FABRICATION PROCEDURE

EQUIPMENT : DEAERATOR WITH STORAGE TANK

DOCUMENT NO : ENV-SPV-DR-B-003

VENDOR SERIAL NO : J. 2267

CONTRACT / PO NO : TBA

COMPANY : PT. SOUTH PACIFIC VISCOSE

PROJECT : TBA

LOCATION : PURWAKARTA - JAWA BARAT

COMPANY APPROVAL

YOEY GARCIA 13-10-2020

PT. SOUTH PACIFIC VISCOSE

Issued for Oct

A
Review 01,2020
Rizki Perbawa Yan Rizal Aan Hendriyana
Prepared by Reviewed by Approved by
Rev Description Date
PT. ENVICON EKATAMA
 DOCUMENT NUMBER Rev
FABRICATION PROCEDURE
ENV-SPV-DR-B-003 A

COMMENTS RESPONSE SHEET

Document /
No Company Comments Contractor Response Initial Remark
Page Ref
 FABRICATION PROCEDURE

TABLE OFCONTENT

1. SCOPE
2. PURPOSE
3. ABBREVIATION
4. RESPONSIBILITIES
5. REFFERENCES
6. FABRICATION PROCEDURE
6.1 RAW MATERIAL IDENTIFICATION
6.2 MARKING CUTTING
6.3 ROLING
6.4 FIT UP
6.5 WELDING CONSUMABLE CONTROL PROCEDURE
6.6 WELDING
6.7 NOZZLE FABRICATION AND INSTALLATION
6.8 VISUAL INSPECTION
6.9 NDE EXAMINATION
6.10 NDE FREQUENCY for RT, MPI, UT, DPI
6.11 PROGRESSIVE EXAMINATION
6.12 DIMENSIONAL CHECK
6.13 SANDBLASTING AND PAINTING
6.14 DELIVERY
7. FABRICATION FLOW CHART

REVISION RECORD

Nov 15,
3
2019
Hadimas RS Yan Rizal Aan Hendriyana
Nov 09,
2
2019 Hadimas RS Yan Rizal Aan Hendriyana
Nov 07,
1
2019 Hadimas RS Yan Rizal Aan Hendriyana
October
0
26, 2019 Hadimas RS Yan Rizal Aan Hendriyana
Prepared By Reviewed By Review/App’d By Review/App’d By
Rev Date
QA.Engineer QC Supervisor QA/QC Dept. Mgr CLIENT

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 FABRICATION PROCEDURE

1. SCOPE
This procedure is applicable the STORAGE TANK & DEAERATOR PPL#1 Project,
fabrication of PT. South Pacific Viscose
2. PURPOSE
This procedure defines the guidelines for the material identification, marking,
cutting, fit-up, welding, nde & painting for the above mentioned items. Each
fabrication technique shall be in accordance with accepted ASME VIII and shall be in
accordance with the requirements of all applicable specifications.
3. ABBREVIATION
WO : Work Order
QA : Quality Assurance
QC : Quality Control
NDT : Non Destructive Test
NDE : Non Destructive Examination
RT : Radiographic Test
UT : Ultrasonic Test
MT : Magnetic Test
PT : Penetrant Test
WPS : Welding Procedure Sfecification
PQR : Procedure Qualification Record

4. RESPONSIBILITIES
4.1. QA–QC Manager/Supervisor
4.1.1. Receiving copy of WO from engineering department.
4.1.2. Determining product Inspection and Testing Checklist form.
4.1.3. Assigning inspector to conduct an inspection on stages of production
process, using as guidance the available checklist.
4.1.4. Giving status identity of nonconformity to products as follows “X” (cross
mark) on part of product that need to be repaired “writing” in case of
inadequacy in product quality requirements.
Informing production department of any finding of nonconformity
to be immediately repaired.
4.1.6. Ensuring that recheck has been made on reworked products.
4.1.7. Asking inspector to return check sheet if the product have been
inspected and tested.
4.1.8. Ensuring that all items of inspection and testing specified in check
sheet have been marked “OK “.
4.1.9. Preparing report on inspection and testing finished products in the
form of QC report using Report on inspection and testing of finished
product form.
3.1.10. Documenting all results of product inspection and testing
4.2. Production Manager/ Contruction Manager
4.2.1. Notifying QA department that finished products are ready to be
inspected.
4.2.2. Reworking on products that are identified as non-conforming by
QA department.
4.2.3. Re-notifying QA department of products that have been reworked

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4.3. QC Engineer
4.3.1. Planning, Monitoring, Controlling and Optimizing QC inspectors and
their daily activities for achieving to the progress
4.3.2. Planning, Monitoring, Controlling and achieving product’s
certification progress
4.3.3. Planning, Monitoring, Controlling Welding and NDT activities (RT,
UT, MT, PT) whichever is applicable and ensuring meet to the Code,
Specifications and Regulations
4.3.4. Planning, Monitoring of inspection and fabrication tools for ensuring in
fit and calibrated condition
4.4. QC Inspector.
4.4.1. Responsible to make sure that only approved procedure
4.4.2. Ensuring Design and Fabrication comply with applicable Code/
Standard
4.4.3. Responsible and handle welding quality, NDT (Non Destructive
Test) process
4.4.4. Prepare Materials Traceability, Welding, Dimension, NDT and Testing
report and compiling them as a package of as built certification dossier
4.4.5. Has responsibility as welding inspector and make report related to
welding quality
4.4.6. Controlling tools for inspection and fabrication in calibrated condition
and fit to used

5. REFERENCES
5.1. Inspection & Test Plan.
5.2. Fabrication drawing
5.3. ASME Sect V, VIII & IX; Latest Edition
5.4. Material receiving procedure
5.5. Calibration procedure
5.6. NDE procedure
5.7. WPS & PQR
5.8. Welder certificate

6. FABRICATION PROCEDURE
6.1. Raw Material Identification
Specified of raw material identification follow to document Material Traceability
Procedure
6.2. Marking Cutting
6.2.1. All material shall be identified like heat no, material specification, size
and visual. Before cutting Heat Number shall transfered on material.
6.2.2. Material Test Certificate shall be accordance with the actual material
will be used.
6.2.3. Marking and cutting on the plate, pipe shall be as per drawing
dimension.
6.2.4. All the cutting surface shall be grind smooth before fit up.
6.2.5. All stencil marking and cutting should be inspection by QC.

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6.3. Rolling
Fabrication of Storage Tank & Deaerator PPL#1 Project use Cold rolling
methode.
Before rolling process, ensure corrected development as per required. If pre
bending is required, to get the good result before rolling chimney plate should
be extended minimum 100 mm. ?????????????
6.4. Fit Up
6.4.1. All fit up shall follow the drawing design.
6.4.2. All the fit up shall be check by QC and refer to AFC Drawing and
Standard Code.
6.4.3. All gap, beveling, root face for welding shall be check by QC inspector,
refer to WPS / PQR.
6.5. Welding Consumable Control
Specified of Welding Control Consumable follow to document Welding
Consumable Control Procedure.
6.6. Welding
All code welding shall be in accordance with the 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. Welds shall be continuous. Butt welds
between materials of different thickness shall be tapered by grinding the
thicker parent materials at a taper of 1 in 3 as minimum 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 MPI upon adequate surface dressing of the weld.
6.6.1. Welding Equipment
To ensure the production of sound weld, 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
adjustment 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.
6.6.2. Preheat and Interpass Temperature
Welding preheat and interpass temperature shall be as specified in
the qualified welding procedure specification. For preheating of
material greater than 2.5 inches and over where continuous
preheating by using flame torch is impracticable, than electric heating
element may be used as an alternative. Preheat must be performed
before any welding commence, including tack welding.
When specified in procedure qualification. Preheat shall be
established for a distance of at least 3 inches on either side of the
weld line and throughout the wall thickness. Preheat temperature shall
be measured by thermocouple, temperature indicating crayons or
pyrometers. In all cases, regardless of the thickness, interpass

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temperature shall not exceed 600o F (315o C) unless a greater

temperature is recorded in the procedure qualification.
6.6.3. Weld Profile
Where shown in the specification drawing or required by the code
requirement, weld profile control shall be carried out to improve the
fatigue life if the material. The surface reinforcement profile shall be in
accordance with ASME Construction Code acceptance criteria.
See appendix 1 for “Acceptable and Unacceptable Weld Profiles”.
6.6.4. 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 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
feather edge and completely fuse with the root run should they be
part of the completed weld. Only qualified welder shall making tack
welding. AFTER REMOVE ALL WELDING TEMPORARY ATTACHMENT/TACK WELD,
SHALL BE DPT
6.6.5. Fit-up Alignment
When required, stiffeners shall be fitted accurately, neatly and tightly
to transmit bearing loads. Stiffener end shall be on ground smooth to
conform the geometry of the stiffener member to assure 100 percent
fusion in the root of the weld. In the event that joint fit- up
tolerances for production weld exceed permitted values, build up the
joint surfaces via weld buttering is permissible, using a qualified
approved, weld buttering procedure. Excess root opening at welds
may be repaired by depositing weld metal from one side only, by
applying weld build-up to their side of the joint. 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. Alignment tolerance, see figure 1.
6.6.6. Temporary Weld
Temporary weld on items such as handling attachments and
t e m p o r a r y lugs, shall be minimized. When use handling
attachments and t e m p o r a r y lugs the welding shall be performed
with the same care, materials, process, minimum preheat and welding
procedure as permanent welds.
During subsequently removed the temporary attachment with an oxy-
acetylene torch or arc gouging, if any damage on parent material the
depth no closer than 1/8 inch (3.2 mm) from the surface of the
material. Temporary weld do not removed by hammering.
If any damage material during removed temporary attachment, the
material shall be build up and grinding. Then the surface of material
DPT
and build up area shall be inspected by MPI.
DPT
If any defect found during MPI shall be repair as per repair procedure.

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6.6.7. Weld Repair

The Production Department shall repair the defect in accordance
with the approved welding specification and repair weld procedure
shall be approved by client.
The Production Department shall notify QC Inspector about any repair
welds performed to correct weld defect, weld bevel
imperfection and/or base material defect or imperfection. The repair of
defect in weld deposits or base metal shall be approved by QC prior
to executing the repair shall have right to witness such repair.
Removal of the defect may be any method which produce a clean
Surface for the installation of the repair weld deposit. Detail of all
defect and their subsequent repair shall be documented, for insertion
in the inspection report.
Crack, plus approximately 2 inches ( 50 mm ) of sound metal at each
end, shall be removed ( by grinding ) to sound metal. DPT DPT or MPI is
required to verify complete removal of the crack. The entire weld joint
shall be removed if in the opinion of QC Inspector, the material cannot
be properly inspected or repaired or if the weld is rejected.
6.7. Nozzle Fabrication and Installation
6.7.1. Fabrication
During fabrication, it is ensured that the flanges and pipes used follow
the specifications that have been stated in the fabrication drawings.
Make sure the flange is used, rating and type according to drawing.
Make sure the pipe specifications and the pipe schedule used are in
accordance with the drawing. Bevel preparation, welding process shall
follows the WPS and Welding Map. Weld size during welding shall
follow the fabrication drawing.
6.7.2. Installation
Ensure orientation and elevation shell be follows the fabrication
drawing.
6.8. Visual Inspection
Each weld appearance shall be in accordance with requirement of the related
Code Construction. Specified applied follow to document Visual Inspection of
Weld Procedure
6.9. NDE Examination
Specified Methode and applied of NDE follow to NDE Procedure and document
Inspection Test Plan
6.10. NDE Frequency for RT, RT, DPT AND
MPI, UT DPI
UT,
NDE Frequency as follows:
6.10.1. NDE as follows :
 Radiographic Testing :100% UT TESTING : 100%
 Penetrant Testing : 100% (WELDING NOZZLE AT
HEAD)
6.10.2. Site Fabrication
6.11. Progressive Examination
If a joint welding is repaired by RT, progressive examination is applied with the
provision additional two sheets of film before and after area the joint welding
which is radiographic test. If an additional radiographic joint still found to
be repaired, additional sheet of film is applied again one sheet before the

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additional sheet film for joint welding and one sheet of film after the additional
sheet film for joint welding. This process is carried out until additional joint for
radiographic is accepted
6.12. Dimensional Check.
Specified of dimensional check follow to document Dimensional Control
Procedure
6.13. Sandblasting and Painting
Specified of dimensional check follow to document Surface Preparation &
Painting Procedure
6.14. Delivery
6.14.1. Check completeness all accessories.
6.14.2. Check Packing List refer to document Packing and Preservation
Procedure

7. FABRICATION FLOW CHART

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Fabrication Flow Chart

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Figure 1 (Alignment Tolerance)

Appendix 1 : Acceptable and Unacceptable Weld Profiles

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