MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

CONTENTS

SECTION NO TITLE

1.0 SCOPE

2.0 REFERENCE & CODE STANDARD

3.0 GENERAL FABRICATION REQUIREMENTS

4.0 PRODUCTION WELDING

5.0 INSPECTION AND TESTING

1.0 SCOPE
Fabrication & Inspection Procedure Page 2
 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

This procedure details the requirements for the welding and inspection in the shop
fabrication of Piping and Pressure Vessel.

2.0 REFERENCED DOCUMENTS

The following standards and code shall be considered part of this procedure :

- ASME Section VIII Div. 1, 2007 Ed. Add. 2008

- ASME Section II, 2007 Ed. Add. 2008
- ASME Section V, 2007 Ed. Add. 2008
- ASME Section IX, 2007 Ed. Add. 2008
- American Welding Society (AWS) D1.1, Latest Edition
- ASME B31.1 / B31.3, Latest Edition

3.0 GENERAL FABRICATION REQUIREMENTS

Fabrication welding includes the inspection of material, equipments, workmanship,

testing, and other items required to weld and inspect vessel fabrication.

Each fabrication technique shall be in accordance with accepted current good engineering
practice and shall be in accordance with requirements of all 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 in 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. Butt 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 the joint. When the different of thickness
is less than 3/8” (10mm) the transition may be formed by adding addition weld metal
and MT upon adequate surface dressing of the weld.

Welding shall be done by Shielded Metal Arc Welding (SMAW), Submerged Arc Welding
(SAW) & Gas Tungsten Arc Welding (GTAW).

Weaving shall be limited to a maximum of 2.5 times core wire diameter or 12.7 mm,
whichever is the smaller.

4.0 PRODUCTION WELDING

Fabrication & Inspection Procedure Page 3
 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

4.1 WELDING MATERIALS

Welding material to be used shall be as follows:

a) For SMAW shall conform to low hydrogen E-70XX classification of SFA 5.1
b) For SAW shall conform to classification of SFA 5.17 & SFA 5.23
c) For GTAW shall conform to classification of SFA 5.18 & SFA 5.9
d) For FCAW shall conform to classification of SFA 5.20 & SFA 5.22
e) For GMAW shall conform to classification of SFA 5.18 & SFA 5.9

4.2 WELDING EQUIPMENT

To ensure the production of sound welds, welding machines, line-up clamps,

beveling machines, cutting torches, tools, supplies and other equipment used in
conjunction with the welding work shall be kept 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 equipment
and supplies.

Welding machines shall have adequate controls for making the current
adjustments as necessary for all welding requirements. Sufficient meters, portable or
permanent, shall be provided to calibrate machines and to regulate voltage and
amperage on a regular basis.

4.3 WORKMANSHIP

Shearing, flame cutting, beveling and chipping shall be done carefully and accurately
with an automated or mechanically guided tool, where possible. Any beveled edge
that has been damaged shall be restored prior to welding. The cutting line shall be
marinated to allow the back dressing of 0.5 mm (minimum).
Beveled edge of carbon steel material to be stored for more that two weeks may
be protected by a lead free primer coat, such as deoxialuminate of about 10  m.
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 or
contaminants which might adversely affect the quality or strength of the weld.

Run On - Run Off tabs , used in welding of longitudinal seams and plate splices,
shall be of the same thickness, specification , grade and edge preparation as the
plate being welded. Tabs shall be of a minimum length of 200 with a width of
150 to permit complete freezing of the puddle on the tab before extinguishing 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
distortions.

Fabrication & Inspection Procedure Page 4

 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

The welding arc shall only be struck within the weld preparation or onto already
deposited weld metal. Should arc strikes occur outside the joint, they shall be
removed, flushed and NDE by MT or PT.
It is advisable to use “Striking plate “.

When more than one weld pass is deposited on a joint , each pass shall be
thoroughly cleaned by wire brushing and chipping before the next pass is
applied.

Welding shall not be discontinued until half weld is completed. If interruption

occurs after this stage, such as for inspection etc., then the minimum preheat shall
be ensured before restarting

Weld shall not be quenched or unnaturally cooled and shall be protected from
rapid cooling caused by rain, wind, or inclement weather. Suitable wind breaks /
shields shall be provided during high wind velocity exceed 10 mph.

Completed weld shall be cleaned of any slag residue to permit inspection.

Completed welds shall be clearly marked with welders stamp every 3 ft. to allow
proper documentation of weld or recorded in welding map.

4.4 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 Attachment 1 for “ Acceptable and Unacceptable Weld Profiles “.

4.5 FIT-UP AND ALIGNMENT

When required, stiffeners shall be fitted accurately, neatly, and tightly to transmit
bearing loads. Stiffener end shall be or ground smooth to conform to the
geometry of the stiffener member to assure 100 percent fusion in the root of the
weld.

Excess root opening at welds my be repaired by depositing weld metal from one
side only , by applying weld buildup to their side of the joint (i.e. through
member). The maximum weld buttering 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 employed to close excessively wide root openings.

Fabrication & Inspection Procedure Page 5

 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

In the event that joint fit-up tolerances for production welds exceed permitted
values, buildup of the joint surfaces via weld buttering is permissible, using a
qualified, approved, weld buttering procedure (see Sect. IX for qualification of
Buttering / Built-up and Construction Code).

4.6 TACK WELDING

Tack welding, seal welding, and welding of temporary attachments (Including

scaffolding supports and tie -downs) shall be performed in accordance with the
welding parameters in approved welding procedures.
Tack welds shall have a minimum length of four times the plate thickness, or 2
inches, whichever is less, be ground to a feather edge, and completely fuse with
the root run should they be part of the completed weld. And only qualified welder
shall making tack weld.

4.7 TEMPORARY WELDS

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, processes, 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 dye penetrant test
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.

4.8 WELD REPAIR

A weld repair specification, including the method for removal of defects

preparation of weld area, subsequent nondestructive testing, and the minimum and
maximum repair length/depth shall be prepared by Production Supervisor and
submitted to Q.C. Supervisor for approval and Client for major repair for his
concurrence. The weld repair specification shall be approved before any welding is
performed.

The Production Dept. shall repair the defect in accordance with the approved
welding specification and Company’s Standard Operating Procedure No. QP-02-05
(STANDARD PROCEDURE WELDING DEFECTS REPAIR).
The Production Dept. shall notify QC Inspector and Client about any repair welds
performed to correct weld defects, weld bevel imperfection and/or base material
defects or imperfections. The repair of defects in weld deposits or base metal shall

Fabrication & Inspection Procedure Page 6

 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

be approved by QC and Client prior to executing the repair and Client shall have
right to witness such repair.

Removal of the defect may be by 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.

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
particle examination of the excavated and ground cavity, prior to welding, is
required to verify complete removal of the crack. The entire weld joint shall be
removed if, in the opinion of QC Inspector or Client, the vessel part can not be
properly inspected or repaired or if the weld is rejected.
For detail refer to Standard Operating Procedure No. QP-02-05 (STANDARD
PROCEDURE WELDING DEFECTS REPAIR).

5.0 INSPECTION AND TESTING

5.1 GENERAL

The Client reserves the right to request testing of any welding samples at any
time as necessary to maintain verification of the quality of welding work.

5.2 QUALITY CONFORMANCE INSPECTIONS

5.2.1 GENERAL

This section defines the minimum technical requirements for the inspection of
the Piping & Pressure Vessel structural.

The QC. Dept. Shall inspect and documented all work during
fabrication and assembly through the utilization of qualified quality control
inspectors and NDE personnel’s

The Q.C. Dept. shall provide Client 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 Client, any section requires inspection, the

Production Dept. 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 Client.

Fabrication & Inspection Procedure Page 7

 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

The latest edition of the specifications 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 Client and provide adequate office
space during surveillance visits.

5.2.2 STAGE OF INSPECTION

As a minimum, the inspection stages employed by the QC Inspector for

welded joints shall be as follows :
- Fit-up prior to first pass and where required during thru 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 normally be visual
only, unless one or more of the other techniques described in Para. 5.2.3 are
require to explore the extent of visually observed flaws, or unless previous
production performance indicates that unacceptable flaws may be presented.
Inspection at weld completion shall be carried out, as instructed in this
specification, by one of the methods listed in 5.2.3.

Welds in High Strength Material (50 ksi yield and above), due to the
possibility of delayed hydrogen cracking, shall be Non Destructive
Examination no less than 48 hours after welding.

If difficulty is experienced in evaluating defects revealed by radiography,

then ultrasonic test may be as an alternative means, subject to Client
approval.

5.2.3 METHODS OF NONDESTRUCTIVE INSPECTION OF WELDS

Visual Inspection

Visual Inspection of the stages listed 5.2.2, shall include, but not limited to
the following :
- Each weld appearance shall be in accordance with the requirement of
the related Code Construction.
- Each weld surface profile shall be in accordance with Section 4.5
- Each weld attaching internal ring stiffeners
- Other welds in addition to the above, as specified by QC. Inspector or Client
Fabrication & Inspection Procedure Page 8
 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

Radiographic Examination

The QC Dept. shall submit the Radiographic examination procedures to

ASNT/NDT Level III for review and acceptance. ASNT/NDT Level III reserves
the right to test the Shop’s radiographic examination procedure to ensure
that the procedure meets Construction of Code requirements.

The shop’s radiographic examination procedure shall be capable of detecting

the welds flaws permitted by the acceptance criteria of the ASME
Construction Code.
X-Ray or gamma ray techniques may be used.

Film exposure techniques and processing shall provide a film free from
defects, which will show a 1.8% X-Ray and 2% Gamma Ray sensitivity
based on the nominal wall thickness.

The shop’s / sub-contractor shall comply with the safety requirements of

current Indonesian 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 any place.

Radiographers shall be qualified as a minimum in accordance with SNT

-TC-1A Level II or equivalent.

All films shall be identified by job number, weld number, thickness, diameter
and welder stamp as a minimum to allow full traceability. Film shall be
held for storage in a film safe box. as part of inspection records, and retain
for at least for 5 (five) years.

For detail refer to Standard Operating Procedure No. QP-04-02 (STANDARD

PROCEDURE FOR RADIOGRAPHIC TESTING).

Ultrasonic Examination

Fabrication & Inspection Procedure Page 9

 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

The shop’s/sub-contractor ultrasonic examination procedure shall be

submitted to QC. Dept. and ASNT/NDT Level III for review and acceptance.

As a minimum, the shop sub-contractor procedure shall be capable of

defecting any weld flaw permitted by acceptance criteria stated in the
related ASME Construction Code.

QC. Inspector and ASNT/NDT Level III reserves 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
inadequate, QC / ASNT/NDT Level III reserves the right to change the
procedure to one that gives required weld flaw sensitivity.

Ultrasonic operators shall be qualified in accordance with SNT-TC-1A Level

II or equivalent.

Refer to Standard Operating Procedure No. QP-04-03 (STANDARD

PROCEDURE FOR ULTRASONIC TESTING).

Magnetic Particle Inspection & Dye Penetrant Test

The shop sub-contractor shall submit the MT/PT procedure to QC and

ASNT/NDT Level III for review and acceptance.
The MT/PT procedure shall be in accordance with Shop’s Standard Procedures.
Acceptance level shall be in accordance with related ASME Construction Code.
QC and TPI reserves the right to test the shop/sub-contractor’s procedure
to ensure that the procedure meets Code’s requirements.

Inspectors using MT/PT shall be qualified as a minimum in accordance

with SNT-TC-1A Level II or equivalent.
Refer to Standard Operating Procedure No. QP-04-04 (STANDARD
PROCEDURE FOR MAGNETIC PARTICLE TEST) and QP-04-05 (STANDARD
PROCEDURE FOR LIQUID PENETRANT TEST).

Attachment 1
Acceptable and Unacceptable Weld Profiles

Fabrication & Inspection Procedure Page 10

 MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

GEM/XXX.XXX-PROC-XX Rev. 0

Fabrication & Inspection Procedure Page 11