CIVIL CONTRACTOR DOCUMENT REVIEW

CIVIL
CONTRACTOR DOCUMENT REVIEW
REVIEW
MECH
LOG DATE ELECT
IN COMM NO. I&C
A APPROVED SUPORT
B APPROVED AS NOTE CONTRACTOR
C NOT APPROVED RECORD

I INFORMATION WORKING DOCUMENT
DISTRIBUTION
APPROVAL DOES NOT RELIEVE CONTRACTOR
FROM RESPONSIBLE FOR ERROR OR
DEVIATIONS FROM CONTRACT
REQUIREMENTS
BY : DATE :
LOG DATE
OUT COMM NO.
0 15.01.2021 Issued For Approval Iwan M Iwan W
REV. DATE DESCRIPTION PRPD CHKD APPD
OWNER :
PT. PLN ( PERSERO )
Jl. Trunojoyo Blok M I/135, Kebayoran Baru Jakarta 12610
Phone : +62-21-7261875,7261122,7262234, Fax : +62-21-7221330
e-mail : webmaster@pln.co.id
Contract Agreement No. 1594.PJ/DAN.02.01/DIR/2016
PROJECT :
KALSELTENG 2 CFSPP (2x100MW)
PT. PLN ( PERSERO ) PUSAT MANAJEMEN PROYEK

PLN
DOC.NO. 1 0 1 1 8 B - 0 0 - C - 0 6 - Y Y A - 6 2 7 - 0 1 - 0
CONTRACTOR :
CONSORTIUM OF
PT TRUBA JAYA ENGINEERING – ITOCHU CORPORATION – HYUNDAI ENGINEERING CO.,LTD.
SUB CONT./VENDOR
DOC. NO. REV. 0
PREPARED BY Jan. 15, 2021 TITLE

PT WTA Iwan M
CHECKED BY Jan. 15, 2021 GENERAL REPAIR METHOD STATEMENT FOR STEAM TURBINE
AND CENTRAL CONTROL BUILDING
Cont. Consortium Iwan W
APPROVED Jan. 15, 2021 CONTRACTOR DOCUMENT NUMBER REV.
PT PLN PUSMANPRO IKCP0-YYD-A-13-103-26 0

OWNER PROJECT CONTRACTOR DOC. NO.
KALSELTENG 2 CFSPP (2x100MW) IKCP0-YYD-A-13-103-26
CONTRACTOR TITLE ISSUED DATE

January 15, 2021
General Repair Method Statement of Steel
Structure Column Repair for Steam Turbine PAGE REVISION
and Central Control Building 2 0
TABULATION OF REVISED SHEETS
REVISION REVISION
SHEETS SHEETS
A B A B
1 27
2 28
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

January 15, 2021
Contents
GENERAL
1. GENERAL ···························································································································································· 5
2. GENERAL METHOD······································································································································· 5
3. STANDARD REFERENCES ··························································································································· 6

3.1 DIMENSION TOLERANCE FOR ERECTION………………………………………..…..6
3.2 STANDARD REFFERENCE FOR SITE REPAIR WELDING….……………………8
3.3 TOLERANCE FOR PROBLEM ………………………………………………………………..…9
4. TOOLS AND EQUIPMENT…………………….………………………………………………………….…………........9
5. NONCONFORMITY LIST AND REPAIR PROCEDURE…………………………………………….……….13

5.1 NONCONFORMITY STEEL MEMBER DIMENSION……..…………………………….…….….13
5.2 NONCONFORMITY STEEL DEFECT…………………………………………………………….…….….14
5.3 NONCONFORMITY PART ACCESSORIES……………………………………….……………………15
5.4 NONCONFORMITY HOLS….…………………………………………………………….………………..…16
5.5 NONCONFORMITY STEEL PAINTING………………………………………………………………...18
5.6 NONCONFORMITY WELDING .………………………………………………………….……………….19
5.7 NONCONFORMITY STEEL BOLTING POSITION..……………………………………………….20

January 15, 2021
1. GENERAL
This procedure cover the repair method at site location and only used based on project needed.
And it is reffering to permissible standard for accurate repairment method.
2. GENERAL METHOD
NCR
• CONFORMITY ON FIELD
• CONFIRM WITH
ENGINEERING/QC DEPT.
• REPORT NON CONFORMITY BY
OWNER/CCLIENT/INTERNAL
QC
2.2 COLLECT
DATA
2.3 PROBLEM IDENTIFICATION
NO
2.4 REPAIR
PERMIT
YES
2.5 ACTION REPAIR
A

January 15, 2021
A
A
A
2.6 JOIN NO
INSPECTION
YES
2.7 END
3. STANDARD REFERENCES
3.1 Dimension Tolerance for Erection
In order to solve problems appropriately , there needs to be a guide so that the resolution is in
accordance with the general guidelines that have been approved upon. For the repair work of the
dimensions of the column structure, the standard that becomes reference is AISC Code of
standard . ( written on PLN Book 2 of 5 Sub. Section 4.5.7.-18 )
Figure 3.1
Dimensional problem solving mostly used a welding process to repair. According to ITP, the
standard use for welding is AWS D1.1 , it contains all the welding procedure due to project needed.
This table below, gives an information about joint type that we want to apply to the materials.

January 15, 2021
The table shown how to do the preparation before repair welding process and value of material fit
up gap with permissible condition to process welding.
Dimensional Tolerance of welded structural members shall conform to the tolerances of:
(1) The general specifications governing the work, and

(2) The special dimensional tolerances is interpreted as a compression not tubular member.
Straightness of beam and girder for welded beam and primary building members, regardless of
cross section, the maximum variation in straightness shall be :
1
𝑖𝑛 = 𝑁𝑜. 𝑜𝑓 𝑓𝑡 𝑡𝑜𝑡𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ/10
8
1 mm x No. of meters of total length
( AWS D1.1 2015 page 216 )
Straightness of intermediate stiffners
The out of straightness variaton of intermediate stiffners shall not exceed ½ in (12mm) for girders up
to 6ft (1.8 m) deep, and ¾ in (20 mm) for girders over 6 ft (1.8 m) deep, with due regard for
members which frame into them. ( AWS D1.1 Page 217 ).

January 15, 2021
3.2 Standard Reference for Site Repair Welding
The removal of weld metal or portions of the base metal may be done by machining, grinding,
chipping, or gouging. It shall be done in such a manner that the adjacent weld metal or base
metal is not nicked or gouged. Oxygen gouging shall only be permitted for use on as-rolled
steels. Unacceptable portions of the weld shall be removed witout substantial removal of the
base metal. The surfaces shall be cleaned thoroughly before welding. Weld metal shall be
deposited to compensate for any deficiency in size. ( AWS D1.1 Page 218 )
3.2.1 Incomplete Fusion, Excessive weld porosity or Slag inclusions
Unacceptable portions shall be removed ( see 3.2 ) and rewelded.
3.2.2 Cracks in Weld or Base Metal
The extent of the crack shall be ascertained by use of acid etching, MT, PT, or other
equally positive means; the crack and sound metal 2 in (50 mm) beyond each end of
the crack shall be removed, and rewelded.
3.2.3 Localized Heat Repair Temperature Limitations
Members distorted by Welding shall be straightened by mechanical means or by

application of a limited amount of localized heat. The temperature of heated areas are
measured by approved methods shall not exceed 1100° ( 600°C ) for quenched and
tempered steel nor 1200° ( 650°C ) for other steels. The part to be heated for
straightening shall be substantially free of stresses resulting from external forces,
excep those stresses resulting from a mechanical straightening method used in
conjunction with the application of heat.
Engineers approval prior of the engineer shall be obtained for repair to base metal ( other than
those required by ), repair of major or delayed cracks, repair to ESW and EGW with internal defects,
or for a revised design to compensate for deficiencies. The engineer shall be notified before welded
member are cut apart.

January 15, 2021
3.3 Tolerance for problem shown on point 1.1.e and point 1.3 :
Placement of embedded items, allows a tolerance on vertical, ateral, and evel alignment of ±1 in.
AISC, section 7.5, installation of anchor rods, foundation bolts and other embedded items, states
that the variation in dimension between the centers of any two anchors rods within an anchor rod
group shall be equal to or less than 1/8in.
4 TOOLS AND EQUIPMENT
Proper tools and equipment needed to make the process became precise and more easier to do.
There some tools that needed before doing the work process :
Safety Equipment Description Purpose

Googles Covering Eye

January 15, 2021
Welding mask Covering face from arc

radiation
Gloves Covers Hand
Appron and long sleeves Covers body and arms
Tools Description Purpose

SMAW Equipment Tack Welding Process
GMAW Equipment Welding Process


January 15, 2021
Grinder Finishing Weld Process or

remove unwanted slag
Cutting Torch Material Cutting and Pre

heating Process
Gas and Oxygen Tank Support cutting torch
Measurement Tools Description Purpose

Total Station Finding cooridinate and
center line of pedestal and
anchor bolts

January 15, 2021
Meter gauge Short metering
Roll meter Long metering
Vernier Caliper To measure diameters, hole

depth or plate thickness
Lifting Equipment Description Purpose

Webing sling Support equipment for lifting
Crane 55 ton Lifting equipment


January 15, 2021
5. NONCONFORMITY LIST AND REPAIR PROCEDURE
Steel structure work that involves many processes , results in a reduced level of accuracy. The
various problem that occur must be analyzed pricesely and systematically. Therefore it is necessary
to have a problem statement so that it can be resolved correctly.
Fabrication process as the first step of steel structure work must prioritize the quality of materials
and the machining process so that the level of precision is maintained. Machining process can be
interrupted by many factors such as measurement point, drawing mistake or the machine itself. The
problem will hinder the erection process.
To save time and costs, on-site repair procedures should be developed by analyzing future
problems that will hinder the erection process.
5.1 NONCONFORMITY STEEL MEMBER DIMENSION
This is one of the most common problems in steel structure work. There are some types of
dimension problem that will be mentioned below :
5.1.a Un-matched size
It covers length, wide, height, and all the material ( beam ) accessories positions that
include on it, should be measured precisely before the erection. For more details, see figures
5.1.a
Figure 5.1.a
The picture showed that the base plate is 5mm longer from the design. It can cause the
building elevation rise. The repair method will be :

January 15, 2021
• Re-measurement Foundation
Before repairing the material, re-measurement of the foundation must be done first to
ensure that the problem does not lie with the foundation, including re-measuring the
grouting.
• Elevation Check
After dimension check, the next step is measuring the construction member elevation in
order to get the top value of column. We should find the actual value of grouting and top
of column. Therefore, we have an actual value of the member.
• Material cutting
For problem 1.1.a. the grouting must be reduced and adapted to elevation requirement.
Material cutting should be done as it shown on AWS for standard references along with
grouting height reducing process for time efficiency.
Actually, this kind of material problem should be re-fabricated. It will be build with same
strength and precision. For time efficiency, finding innovative solution would be an advantage
as long as it refer to engineering calculations and standard.
5.2 NONCONFORMITY STEEL DEFECT
This caused commonly by the unloading process. Incorrectly technical lifting can be
result of the broken material. it is a major problem and it requires careful handling to solve.
Figure 5.2.(1) Figure 5.2.b (2)
Before determine the solution, in-depth analysis is the first thing to do. We have to see where the material
breaks, whether it can be finish by repair welding, or we have to cut it first so that the dimensions are
back according to the design or close to the permissible tolerance. Figure 5.2.b (1) as an example, the
repair method should be :
• Heat Treatment
Purpose of this process is to compound the base metal with the applied welding and to reform the
base metal so it can be proper and to reduce the gap.

January 15, 2021
• Repair Welding
After the heat treatment process, welding should be applied using perimisible standard. It shown
how much gap that allowed and what kind of welding process can be applied based on material
specifications.
Same solutions can be applied for the figure 1.1.b (2) , but we should pay close attention at the final gap
after the heat treatment and match with the standard. If the gap value was not allowed, the last option is
re-fabricated the broken material.
5.2.a Buckling beam
Theoritically, fatigue on steel structure can be happened by stress at some point of the material
which cannot be overcome by the properties of the material. ( overload ), in some case, it caused by
storage error or forced loading process when the shipment.
Figure 5.2.a. (1) Figure 5.2.a. (2)
Repair method will be :
• Heat treatment
Depends on how many area that buckled, Heat treatment is the first step to do
repairment.it will be need more time and condition of the material itself to solve.
• Bending
The second alternative to overcome buckling, is making a temporary holding device ( jig
and fixture ) to press or pull material precisely. But still need a proper heat treatment
along the process.
• Engineering Calculation
All types of problems at point 5.2 should be re-calculated by authority engineering

department to make sure that the repair processes are appropriate to the design. And
should be approved
• Re-painting
After forming processes were done and approved, the material should be re-painted by
Refering to coating standard shown on fabrication ITP.

January 15, 2021
For buckling , twist , etc which damage to bracing, beam, girder, insert, gusset, as long as
it’s not affect to material strength and dimension, we can do the repair on site location.
For injured and broken part should be replaced with the new part. If it can be repaired by
welding process, it should have an engineering calculations and approval by author engineer
department.
5.3 NONCONFORMITY PART ACCESORIES
Mass fabrication process and the difficultness level of the beam design, result an
incomplete parts or not installed parts because of human error. Erector team should provide a
qualified welder to joint its parts
Fig 5.3
Fig. 5.3
Repair Method :
• Re-joint part
When the fabricator sent the incomplete parts, qualified site welders as an executor
should joint it with permissible standard welding. And pay attention about the dimensions
after re-joining process.
Re-joining missed part can be done at height considering time and efficiency as long as it have
Working permitted by safety department.

January 15, 2021
5.4 NONCONFORMITY HOLES
Before the erection process executed, site location surveyors should check the pedestal
and anchor bolts. Whether is it too wide or too small distance between the pedestal members.
Casting concrete work can make anchor bolt center line disturbed.
Fig. 5.4.1 Fig. 5.4.2
It is one of the common things happened in errection process. It is not allowed to do the
enlargement hole size with heating process.
• Remove Gusset
This procedure needs the surveyor to get value of verticality before determine the new
hole diameter. Gusset should be removed by cutting process and re-fabricated.
• Re-joint Gusset
After engineering calculations and approved, the new fabricated gusset should be joined
by welding process and should refer to permissible welding standard.
• Re-painting
As the final process, paint the material by refering to the standard of coating process, and
check the thickness with Elcometer on each layers.
5.4.1 Misplaced accessories position
This problem is also the common things happened at steel structure fabrication.
Considering the difference between the column design and mass production of the material. This
actually miss leading of quality control at the fabrication. And it can be done at height as long as
permitted by safety department.

January 15, 2021
Figure 5.4.1.b
It is very not recommended doing repair at that point. The material should be lifted by crane and
should be on lay down position to repair. Here is some alternative to solve this problem :
• Cutting material
Before determining to cut the material, we have to lowered it down until it lays on the ground. Make
sure the new right position according too the design and marked it with an obvious marker. Use
cutting torch to cut it, plug the accessories into the new position and joint it by welding process.
• Finishing process
After all the cutting process which mentioned above were done, paint it using the premier top coat
according to determine coating shown on the standard.
5.5 NONCONFORMITY STEEL PAINTING


January 15, 2021
Material can be injured by many factors such as, incorrect painting process , loading-
unloading process, storaging, even the area of storage. It cannot be avoided considering the
difficulty of that process above. There are two categories of injured material, Major and Minor.
For example :
Fig. 1.f a ( corrosion ) Fig. 1.f.b ( scratch ) Fig. 1.f.c ( scratch )
The figure shown a typical material injured such as corrosion and scratch. It classified to a minor
reject because it doesn’t affected to the overall material dimension. The material will be touched
up by painting process if the depth of scratch doesn’t injured the material itself.
Corrosion problem
Steel material contains amount of ferrous which can be reacted with the weather
and caused corrosion. Such as figure 1.f.a , when the material have a corrosion problem, the
repair method is :
• Remove the corrosion with sandpaper
If the area of corrosion were large, use a handtool such as grinding machine so it can be
faster. Past the grinding machine with sandpaper along the area of corrosion and make
sure that the surface is smooth and check the thickness of the material. Do not let it
reduce because of the sandpaper process. Use the primer coat which shown on
fabrication procedure to repaint the material.
Scratch
It is classified to a minor repair. This can be happened if the handling process were
not right. The solution can be done in site location would be :
• Re-paint
To do this process, the workers should make sure how many scratch point at the material.
Before do the painting process, use sandpaper to smooth the surface, then use the paint
spray to color the scratch, and check the thickness of painting.
• DFT Check
As the final inspection, DFT check should be done in every layer of coating to make sure

January 15, 2021
coating quality.
5.6 NONCONFORMITY WELDING
The fabricated material sometimes are welded by manual process and it caused some of the
welding problem at some point. Crew at the site location should be ready about this possibility.
Some case of welding can be repaired at the location with implementing standard. There are
potential welding problem such as
Over Spatter
1. Too high ampere

2. Distance between electrode and base metal were too far
3. Moisture on the electrode
Porrosity
1. Used electrode moistured or watered

2. Elongation arc
3. Too low ampere
Crack
1. Wrong pick of electrode

2. No pre-heating process
There are many kind of welding problem but the problem shows on the table above are the common
things happened at the location. Repair welding method has the same step to start. We should
marked the repairing area then use a grinder to remove the unspecified area. In order to prevent
over spatter, porosity , and crack, here is some alternatives :
• Over spatter
- The current should be lowered according to recommendations.

- Arc length ( 1,5 x electrode diameter )
• Porrosity
- For special material,use pre heating before start

- Adjust the ampere according to procedure ( AWS d1.1 )
- Do not let the electrode disgrace by moist or water.
• Crack
- Use low hydrogen electrode with high strain characteristic

- Doing preheat and PWHT

January 15, 2021
All welding repair at site location should be re-calculated and approved by authority engineer
And should be checked by NDT to make sure that the welding process does not issued
New defect.
5.7 NONCONFORMITY STEEL BOLTING POSITION
Misalignments do happen from time to time due to issues with installation. Repair method vary
based on time, placement, and severity of the issue.
• Re- centering anchor bolt
Before the erection begin, surveyor should check correctly about the anchor distance. If
the center value is not going too far from the standard, then we can form the bolt into the
center line using short pre-heating while knock the bolt using hammer or simply use a bar
of steel pipe to get the center line back.
Fig. 1.3.1
Fig. 1.3.3
Fig. 1.3.2
If the anchor bolts is misaligned after the column has been set, you can typically slot the base plate
and use a plate washer to span said slot. But if the anchor bolts majorly misaligned (more than a few
inch ), possibility that te erector’s can take should be :
• Cut off the rods and drill in anchor rods

• Use epoxy that aligns with area’s building code
Engineer should be careful to ensure the foundation hasn.t been compromised if going this route.for
more information, always refer to guides and regulations from the AISC.
All bolt tight and inspected on the SS should be painted to avoid corrosion with the same RAL of SS.

January 15, 2021

CIVIL CONTRACTOR DOCUMENT REVIEW

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CIVIL CONTRACTOR DOCUMENT REVIEW

Uploaded by

Copyright:

Available Formats

CIVIL

CONTRACTOR DOCUMENT REVIEW

C NOT APPROVED RECORD

0 15.01.2021 Issued For Approval Iwan M Iwan W

REV. DATE DESCRIPTION PRPD CHKD APPD

PT. PLN ( PERSERO ) PUSAT MANAJEMEN PROYEK

PREPARED BY Jan. 15, 2021 TITLE

APPROVED Jan. 15, 2021 CONTRACTOR DOCUMENT NUMBER REV.

PT PLN PUSMANPRO IKCP0-YYD-A-13-103-26 0

CONTRACTOR TITLE ISSUED DATE

TABULATION OF REVISED SHEETS

CONTRACTOR TITLE ISSUED DATE

3. STANDARD REFERENCES ··························································································································· 6

4. TOOLS AND EQUIPMENT…………………….………………………………………………………….…………........9

5. NONCONFORMITY LIST AND REPAIR PROCEDURE…………………………………………….……….13

CONTRACTOR TITLE ISSUED DATE

2.3 PROBLEM IDENTIFICATION

2.5 ACTION REPAIR

CONTRACTOR TITLE ISSUED DATE

3.1 Dimension Tolerance for Erection

CONTRACTOR TITLE ISSUED DATE

(1) The general specifications governing the work, and

1 mm x No. of meters of total length

( AWS D1.1 2015 page 216 )

Straightness of intermediate stiffners

CONTRACTOR TITLE ISSUED DATE

3.2 Standard Reference for Site Repair Welding

3.2.1 Incomplete Fusion, Excessive weld porosity or Slag inclusions

Unacceptable portions shall be removed ( see 3.2 ) and rewelded.

3.2.2 Cracks in Weld or Base Metal

3.2.3 Localized Heat Repair Temperature Limitations

Members distorted by Welding shall be straightened by mechanical means or by

CONTRACTOR TITLE ISSUED DATE

4 TOOLS AND EQUIPMENT

Safety Equipment Description Purpose

CONTRACTOR TITLE ISSUED DATE

Welding mask Covering face from arc

Gloves Covers Hand

Appron and long sleeves Covers body and arms

Tools Description Purpose

GMAW Equipment Welding Process

CONTRACTOR TITLE ISSUED DATE

Grinder Finishing Weld Process or

Cutting Torch Material Cutting and Pre

Gas and Oxygen Tank Support cutting torch

Measurement Tools Description Purpose

CONTRACTOR TITLE ISSUED DATE

Meter gauge Short metering

Roll meter Long metering

Vernier Caliper To measure diameters, hole

Lifting Equipment Description Purpose

Crane 55 ton Lifting equipment

CONTRACTOR TITLE ISSUED DATE

5. NONCONFORMITY LIST AND REPAIR PROCEDURE

5.1 NONCONFORMITY STEEL MEMBER DIMENSION

5.1.a Un-matched size

CONTRACTOR TITLE ISSUED DATE

5.2 NONCONFORMITY STEEL DEFECT

Figure 5.2.(1) Figure 5.2.b (2)

CONTRACTOR TITLE ISSUED DATE

5.2.a Buckling beam

Figure 5.2.a. (1) Figure 5.2.a. (2)