PT.

KURNIA ABADI PADANG

FABRICATION PROCEDURE

DK DP
Rev Rev Date Description Prepared By Checked By Approved By

Doc. Number : 003-KAP-PCD-FP

Standard Operating Procedure PT. Kurnia Abadi Padang Page 1 of 33

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DERMAGA DKC1, DAN DERMAGA DKC2 003-KAP-PCD-FP

TABLE OF CONTENT

1. QUALITY CONTROL ................................................................................................................................ 3

1.1 GENERAL CAUTIONS IN MANUFACTURING ............................................................................................... 3
1.2. QUALITY CONTROL POLICY AT SUBCONTRACTOR’S FACTORY ................................................................. 4
2. MANUFACTURING STANDAR ............................................................................................................... 7
2.1. FULL SIZE MARKING –OFF WORK .......................................................................................................... 7
2.2. PLATE WORKING STANDARD .................................................................................................................. 7
2.3 CUTTING WORK STANDARDS ................................................................................................................. 10
2.4 BENDING ............................................................................................................................................... 10
2.5 REVERSE STRAIN ................................................................................................................................... 10
2.6 DRILLING .............................................................................................................................................. 10
2.8 TACK-WELDING STANDARDS ................................................................................................................. 11
3. WELDING STANDARD ........................................................................................................................... 12
3.1 WELDING SYMBOLS .............................................................................................................................. 12
3.2 QUALITY MARKS OF WELDMENTS ......................................................................................................... 12
3.3 WELD JOINT STANDARDS ...................................................................................................................... 13
3.4 EXECUTION OF WELDING ....................................................................................................................... 19
3.5 ACTION TAKEN FOR WELD DEFECTS ...................................................................................................... 23
4. PAINTING.................................................................................................................................................. 24
4.1 CAUTION IN PAINTING ........................................................................................................................... 24
5. INSPECTION PROCEDURES AND CRITERIA .................................................................................. 25
5.1. INSPECTION OF MATERIALS ................................................................................................................... 25
5.2 FULL SIZE INSPECTION ........................................................................................................................... 25
5.3 CUTTING INSPECTION ............................................................................................................................ 26
5.4 GROOVE INSPECTION ............................................................................................................................. 26
5.5 DIMENSIONAL INSPECTION .................................................................................................................... 26
5.6 INSPECTION OF APPEARANCE (VISUAL INSPECTION).............................................................................. 26
5.7 VISUAL INSPECTION OF WELDS .............................................................................................................. 26
5.8 PAINTING INSPECTION ........................................................................................................................... 27
ACCURACY OF WELDMENT .............................................................................................................................. 31
6. CAUTIONS IN DELIVERING PRODUCTS .......................................................................................... 32
6.1 ENTRY OF SHIPPING NO......................................................................................................................... 32

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1. QUALITY CONTROL

1.1 General cautions in manufacturing

1.1.1 The window of PT. Kurnia abadi padang shall in principle be the Purchase Department. In an urgent
inevitable case, inform the person in charge of the relevant department.
1.1.2 Keeping a secret
It is strictly not allowed for Sub-contractor or second sub-contractor to leak out the secret of the
drawing, document and any related techniques from PT. Kurnia abadi padang to any others company
or third party.
1.1.3 Even if being a secondary subcontractor, it is necessary to get the approval of the works. So, be sure
to make application for the approval in advance and approval guidance of work with responsibility.
1.1.4 All fabrication activity shall be planned and predicted of the result, so approved Inspection and Test
Plan (ITP) shall be follow as mandatory guidance for each activity.
1.1.5 All comment during inspection shall be on the report form.

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1.2. Quality control policy at subcontractor’s factory

1.2.1. Schematic flow of work 1

Design & detail drawing

Inspection and Test Plan
(ITP)

Material Pull Size

Inspection PT. KURNIA ABADI PADANG Inspector involved

Certificate of material

Cutting

Inspection

Beveling

Inspection

Tack Welding

Welding As approved WPS / PQR

Inspection

Temporary Assembling

Inspection All NDT required shall be completed

Painting Insurance

MDR Inspection Packing & shipment

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1.2.2 Mfg. Drawing & manufacture specification

(1) As for the titled documents, use those having the signs of inspection and approval.
(2) If there is any doubt in the titled documents, ascertain it from the design engineer in
charge
(3) When the titled document has been modified, be sure to replace with the modified one.
When an indication has been received inevitably by the contact with telephone, keep the
following mentioned in the document: name of design engineer, date of contract and
contents of modification.
(4) When it needs to modify the document issued by PT. Kurnia abadi padang in the aspects
of quality control and price, be sure to give notice by a document and modify after
getting the approval of the section in charge.
(5) Control the acquired documents strictly and don’t handle them roughly. Also, on the
termination of manufacture and delivery of the parts, return the documents to PT.
Kurnia abadi padang right off.

1.2.3 Materials to be used

(1) Keep the materials in store in the building or keep them recovered with a vinyl sheet or
something like that for preventing them from getting rusty or fouling.
(2) Further put the marks / on case of materials shall not to confuse with other materials.

1.2.4 Welding
(1) Get the qualified and certified personnel to engage in the welding work.
(2) Put the welding rods in a desecrator to keep drying at a specified temperature.
(3) Never get any unqualified person to engage in the welding work under any
circumstances.

1.2.5 Manufacturing control

(1) Never manufacture nor inspect the parts based on a reference drawing and an estimate
drawing.
(2) In manufacturing, formulate such production plan as to enable maintaining a certain
quality.

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(3) For the tools, nominate a person responsible for managing them to get him to take in-
charge of the daily maintenance and check of these tools.
(4) With adequate personnel arrangement, always check whether the work is going on as
the delivery data schedule for supervising not to delay the delivery date.
(5) Also, inform the work progress condition at least once a week.
(6) Clean the sections inside the factory at the end of every week and try to tidy up.
(7) Give the highest priority to the safety and if there is any improvement or step to be
taken, perform within that day.

1.2.6 Inspection
(1) Be sure to perform a voluntary inspection as per Inspection and Test Plan (ITP).
(2) Submit the application for witness inspection to the Quality Assurance Dept. one week
before as a rule with the required items put in a prescribed form (a request sheet for
witness inspection).
(3) Judgment of OK/NO shall be according to PT. Kurnia abadi padang inspection
standards.
(4) Compile the inspection records with the contents made clear through pre-arrangement
with PT. Kurnia abadi padang inspector.
(5) Submit the specified number of copies of the inspection records to the Quality
Assurance Dept.
(6) Keep the inspection records at least one year. After one year has elapsed, discard the
records.
(7) Calibrate the inspection tools (micrometer, slide calipers, etc.) periodically (preferably
at about 1-year interval)

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2. MANUFACTURING STANDARD

2.1. Full Size Marking –Off Work

2.1.1. As the scale used for full size marking-off, use a scale which has been tape adjusted with the
reference scale (ASME/ANSI) supplied by PT. Kurnia abadi padang.
2.1.2 For the full size, make a full scale original drawing as a rule and do a thread chasing.
2.1.3 Scalloping standard
Scalloping shall be according to the standard given below:
(1) When indicated in the drawing, the scalloping shall be according to the indication in the
drawing.
(2) When not indicated in the drawing:

l=leg length
a) In case of rib plate
thickness being t2<16
m/m
Scallop shall be
l=leg length
b) In case of rib plate
thickness being t2<16
m/m

2.2. Plate Working Standard

2.2.1 Remove paint, oil film, grease, moisture, scale and other foreign matters detrimental to the quality of
deposit metal from the tack-welded surfaces.
2.2.2 For the requirements of tack welding rods, bead length, leg length and preheating, refer to “3.4
Tack-welding standards”.
2.2.3 Carefully and not to produce arc strike inside a groove or on a discarded plate.

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2.2.4 Remove slag produce during work thoroughly during assembling work.
2.2.5 To prevent from shrinkage or deformation, reinforced sufficiently prior to getting work on welding.
The reinforcement must be a proper on size and position to permit withstanding a welding shrinkage
stress.
2.2.6 Assembly based in the center and mark the center used for reference to the last.
2.2.7 Take out all reinforcements.
For removing them, cut by gas cutting, arc air or grinding and be carefully not to damage the base
metal and after cutting, finish smoothly by grinding machine.
2.2.8 For a root gap and groove angle, follow the indications in the drawing or refer to the quality control
standards “Attached data 1. Accuracy of weld joint (groove)”. Also, if there is a defect of the groove
which exerts a bad influence upon the weld quality, remove it before welding.
2.2.9 The weldments of the internal mounting parts must not be covered before the inspection terminates.
2.2.10 Chamfering (1.5c to 2c)
Chamfer the free edges of the major parts by 1.5c to 2c
2.2.11 Dislocation of plate joint, a thinner side shall be within 10% of plate thickness as a target.
2.2.12 Removal of primer on welding section
(1) Wash primer (blue) and Zinc rich primer (gray)
Fillet weldment of main member – 3T

(Example)

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 Web mounting, flange material

 Rib mounting part of more than 14mm in plate thickness
 Reinforcement mounting part of more than L100
 Each wall mounting part

2.2.13 How to attach checkered steel plate

2.2.14 Gradient of joints having difference in plated thickness

(1) In the case of t1-t2 being smaller than 2m/m, t1-t2 < 2 m/m, gradient is unnecessary to
provide. However, the plate thickness shall be up to 25m/m. When surmounting 25m/m, it is
unnecessary to provide gradient up to difference of 3m/m in plate thickness.

e = more than 4 times as much as difference in plate thickness

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2.3 Cutting work standards

2.2.1. Steel plates shall be cut by gas and a shearing machine
2.2.2. For cutting other materials, use an automatic gas cutting machine, manual gas cutting machine and
high speed cutting machine.
2.2.3. After cutting, check for defect (s) on cut faces.
2.2.4. The gas cutting accuracy must be as shown below.

Section Roughness Notch

Inside of groove 200S or less 2mm or less
Free edge 100S or less 1mm or less

2.4 Bending
2.4.1 Do the bending work with the use of press at ordinary temperature in principle, be careful not to
debase the quality of steel materials. However, in an inevitable case, a hot bending work shall be
done.
2.4.2 The hot bending work is done by heating the material more than 900°C as a rule and the bending
work shall not be done in a condition where the material has been cooled down to 200 to 400°C or
there about

2.5 Reverse strain

When there is a need to provide a reserve strain beforehand, do it carefully not to deteriorate the
quality of steel material by press.

2.6 Drilling
2.6.1 Holes must in principle be made by a drill
2.6.2 Remove burrs at the periphery of hole by a grinder

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2.7 Treatment of friction face of friction grip with high strength bolt.
2.7.1 Remove mill scale sticking onto the friction face of member which is friction-joined with high
strength bolt by the following methods.
Section Method
Web of member, flange & gusset plate Shot-blasting or grinding
Spliced plate & filler plate Shot blasting or grinding

2.7.2 A range where surface treatment is given shall be more than 2 times as much as a washer diameter.

2.8 Tack-welding standards

2.8.1 When rust, oil, paint, etc. are found sticking to the weldments, remove these matters before
embarking on the tack-welding work.
2.8.2 For tack welding the inside of groove, use a rod of ø3.2 or ø4
2.8.3 How to execute tack-welding work
(1) For tack-welding, secure a sufficient weld length at a proper position not to come off while
transporting and reversing the sub-assembled products.
Bead length: More than 30mm for plates whose thickness is 25mm or less.
The length shall be 50 mm or more for plates whose thickness
exceeds 25mm.
Pitch: At least 3 spot locations/m.

Crater treatment: Perform a crater treatment fully not to produce crater crack.

Arc start: Do it on a discarded plate

Tack-welding position: Tack-weld so that positions become symmetrical wherever possible

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Tack-welding position Do not tack-weld within a range of 50mm from edge

Avoid tack welding the parts not given regular welding

3. WELDING STANDARD
3.1 Welding symbols
The welding symbols shall be in accordance with international Welding symbols.

3.2 Quality marks of weldments

Shown in Table below is the application guideline by classes of weld quality marks. Its welding is in
accordance with the standard W3

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Quality mark Application guideline given by classes Example of application to

products
W1 1. When it cannot choose but require almost Weld liner
the same joint efficiency as that of base Spider nozzle box
metal especially viewed from the working Nuclear reactor pressure vessel
conditions and structure of a product. High vacuum tank
2. Weldment requiring severe assurance
especially on leakage in terms of working
conditions of a product.
3. When a load working on weldment has an
element hard to estimate and further, trouble
fatal to the product occurs due to breakage
of this weldment.
Weldment requiring especially severe
4. assurance in addition to the above
mentioned.

W2 1. Weldment requiring joint efficiency of 0.9 Turbine casing

in static stress and 0.7 in variation stress Pressure oil
from calculation in general high Tank Rectification tower
temperature and high pressure products, Cold storage tank
pressure vessels, etc. High-temperature, high pressure
Top-class weldment requiring leak vessel & piping
2. resistance
Weldment of extremely low temperature
3. pressure vessel.
Weldment subjected to severe fatigue load
4. and impact load.
W3 1. When precise strength calculation can be Oil tank
cut out and there is no obstacle in practical General piping
use. General weld structure & Pressure
2. In accordance with general welding vessel
standards
W4 1. When purpose lies in joining parts merely Lagging
and weldment is not used as strength Covers
member

3.3 Weld joint standards

3.3.1 Details of joints (groove)

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3.3.2 Butt welding

(1) General items

(1) Butt-weld all joint lines

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(2) The groove profile is shown in Para. 4-3-1

(3) Perform a weld penetration and building-up fully
(4) Weld excess shall be not more than 2 mm

(2) Reinforcement
Reinforcement must be 3 mm maximum

(3) Back chipping

When a back chipping has been indicated in the drawing, does it till a sound deposited metal
appears on the surface.

3.3.3 Leg length in continuous fillet welding

(1) The leg length in fillet welding must be more than a length indicated in the drawing. (No
length smaller than that indicated is allowable).

(2) Type of fillet welded joint

(1) Lap joint

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(2) T joint

(3) When there is no indication of the leg length in the drawing, the leg length shown below
must be applied to ‘Thinner plates’.

Plate 2.3 3.2 4.5 6 9 12 14 16 19 22 25 28 32 36 38 40 45 50

thickness
Leg 3 3 4 4 6 6 8 8 10 10 12 12 14 14 16 18 18 18
length

3.3.4 Intermittent welding

(1) For the weld length and pitch of the intermittent welding, observe the indications in the drawing.
(2) Intermittent welding modes:
a) Parallel intermittent welding

L : Welding length P : Welding pitch

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b) Staggered intermittent welding

L : Welding length P : Welding pitch

c) When the welding length and welding pitch of the intermittent welding are not indicated in
the drawing, do the welding referring to the table below. However, unless otherwise
specified, both ends must be welded.

Plate thickness Welding length – Welding pitch

3.2 mm or less 25 to 75 mm
4.5 to 6 mm 50 to 150 mm
9 to 16 mm 75 to 225 mm

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3.3.5 Standard of joints

(1) For H-steel :

(2) For connecting plates

Be careful not to cross the weld lines with each other

(3) For shape steel :

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3.4 Execution of welding

3.4.1 Welding process

Execute all of welding by using welding process that’s clearly mentioned on WPS/PQR .

3.4.2 Welder
The qualified welders who have received the upper training of PT. Kurnia abadi padang instructor
must engage in the welding work.
Sample of approval / identification after having received upper training:

Welders Approval in accordance with “Welding skill certification”

Welding Type of joint Plate Welding Bending Marking
mode thickness process test standard
Temporary Flat position Butt welding 9 mm Arc Face bend A-2F
assembling of plate welding Root bend
welder
(fitter)
Regular Vertical Butt welding 9 mm Arc Face bend A-2F
welder position of plate welding Root bend

3.4.3 Welding rod

Welding rod shall be selected as approved WPS / PQR and keep dried on desecrator before using,

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3.4.4 Welding conditions

1) Manual welding

2) For back chipping in butt welding (however, exclusion of a case where there is a backing metal),
chip before welding a weld root or doing a back welding and remove defect(s) by a grinder or an
arc air gouging.

3) Be careful not to give arc strike to the base metal and make the arc start inside a groove or on a
discarded plate.

3.4.5 Welding machine

The welding machine and attachments used for the welding work have enough capacity and
performance to the kinds of welding materials (diameters and brands) used and allows the work to
carry out safely.

3.4.6 Management of welding materials

a. Storage of welding materials

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(1) The welding materials, before unsealing and uncasing, must be stored neatly in place which
is safe against moisture, rust and breakage.
(2) The welding materials such as manual welding rods and flux which might get moistened
must be kept in a drying oven or desecrator after having been unsealed and uncased.
(3) The welding materials carried out to the welding worksite must be kept in a proper portable
container.

b. Drying the welding materials

The manual welding rods among the welding materials should be dried in the conditions shown
below before using

Welding materials Drying temp.(°C) Drying time (min.)

Manual welding Low hydrogen type 300 to 350 30 to 60
Other types 70 to 100 30 to 60

3.4.7 Cleaning the members

Straighten each member prior to getting to work on welding and further, clean by removing
detrimental substances sticking to the welding surfaces, e.g., water droplets, rust, paint, oil & fat,
sand and so on, and then start the work.

3.4.8 Fabrication of members

Connect and fabricate the members correctly with match marks by using adequate jigs and tools.

3.4.9 Preheating

When coming under the following conditions, preheat by gas flame over a range of about 100 mm at
one side from the welding line. Also, measure and make sure of the preheating temperature at a
position of about 50 mm away from the welding line by a temperature choke.

Steel plate thickness (mm) Preheating

Under 25 mm No preheating needed
25 mm and over Preheating needed (60°C±10°C)

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Note: When the atmospheric temperature is below 0°C the welding work should be avoided. This
rule, however, does not apply to the case where the atmospheric temperatures ranges from
0°C to 25°C and the welding is done by heating a base metal at a range of 100 mm from the
welding line so that temperature of the portion becomes 36°C

3.4.10 End tab

When it needs to provide an end tab, use a steel tab.

Cut the end tab, leaving 5 to 10 mm

3.4.11. Straightening
Strain generated from welding must be remedied by a press straightening machine or linear heating
method.
A maximum heating temperature by the heating method and the cooling method shall be as follows:
 Maximum heating temperature: 850 to 900°C (Desired temp: 885°C)
 Cooling method: Start forced cooling after stopping the heating.

3.4.12 General instructions in doing welding work

(1) For welding at the shop, employ a flat position welding wherever possible.
(2) Prior to doing a multilayer welding, clean the welding faces every layer and check for weld
defect(s).
(3) In welding, defects are prone to come about at the start and terminal ends and joints of welding
heads. So, do the work with the greatest possible care.
(4) Carry out the welding work carefully so that strain and deformation become minimum.
(5) The welding bead surface must be smooth and have a regular waveform, and the welding
dimension must not be under the design dimension.
(6) In doing the welding work, keep an arch length adequately and perform the welding operation
regularly.
(7) Even for tack-welding, get the welder who has the welding qualification and further, has
undergone the upper training conducted by PT Basuki Adyagrahaniaga to engage in the work.
(8) After welding, clear away spatter and slag thoroughly.

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3.5 Action taken for weld defects

If any defect has been found coming about in the weldment, take the corrective actions referring to
the table below.

Description of defects Influence Probable causes Corrective actions

 Undercut  It turns into notch  Excessive welding  Weld carefully with
 Fatigue strength current thin welding rod
lowers  Improper welding  Do work by proper
 There is danger of operation welding operation
brittle fracture being  Improper type of
generated welding rod
 Overlap  Stress concentration  Excessive welding  Remove lapped part
occurs due to current by grinder and
insufficient fusion  Excessively large dia. perform proper
with base metal and Of welding rod. manipulation
notch is produced,  Slow manipulation
resulting in
debasement of
mechanical properties
 Lack of penetration  Stress concentration  Improper groove  Weld after back
occurs angle chipping
 Mechanical properties  Excessively large dia.  Keep proper root gap
deteriorate Of welding rod  Perform proper
 Excessively small manipulation
root gap
 Excessively small
current
 Fast manipulation
 Blowhole  Small blowholes are  Precipitating together  Re-weld after
hardly affected by with solidification of chipping off.
static load. Shook gaseous body  Dry welding rod
resistance at fatigue contained in deposit sufficiently
and low temperature metal at a time of  Clean weldment
is deteriorated. Also, welding and shut in surface
stress corrosion is by failure to purge  Perform welding
caused.  Sticking of oil paint operation properly.
and rust to weldment
surface and much
moisture
 Wet welding rod
 Crack in deposit steel  Strength is debased  This crack is  Select proper welding
 Corrosion is attributable to rod
generated shrinkage stress of  Improve welding
deposit metal itself manner
and peripheral  Remove cracked part,

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constraint force. The make stop holes at

poorer the toughness both end are re-weld.
of deposit metal is Order of action
and the smaller the
bed length is, the
oftener the crack is
apt to come about at a
time when force of
constrain of
weldment I great
 Improper welding rod

4. PAINTING

4.1 Caution in painting

(1) Carry out the painting as indicated by the manufacture specification sheet.
(2) Prior to embarking on the painting work, remove spatter, rust, combustible and oily content
thoroughly.
(3) Stir the paints well.
(4) Keep the rate of thinner and pigment about 20%: 80%. (Be careful not to dilute too much).
(5) No painting at night or in case of rain, snow and fog.
A preferable painting time is from 10:00 A.M. to 3:00 P.M.
(6) Don’t paint when humidity exceeds 85%. Especially in rainy season, take care.
(7) No painting on a windy day. (When painting outdoors)
Be careful with the sticking of dust.
(8) When a material to be painted is over 30°C, the paint film dries very fast. Be careful.
(9) When using a brush for hand painting, don’t use a used brush nor brush whose surface is
worn out.
In the case of hand painting, apply the paint to manipulate the brush in the same direction.
(10) For spraying, clean the spray gun nozzle and then spray.
(11) Take the sample drying time. Don’t deliver any part soon after having been painted. In a
general anti corrosive coat, take 6 hours in summer season and 12 hours in winter season.
(12) Store the paints in a dark place where temperature is 40°C or below as much as possible.
A paint kept in store for an excessively long period is undesirable.

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Stir the paint in a container unsealed once well before putting it into a sealed container for
keeping in store

5. INSPECTION PROCEDURES AND CRITERIA

5.1. Inspection of materials

For the steel materials to be used, check the size and profiles and roll bars to make sure there is no
abnormality at a time of reception or manufacture.
Also prepare the inspection records of steel materials as sample shown below and then attach the
mill sheet.

Note:
 There mustn’t have any detrimental defect on the material surface
 The material and size must be as specified.

5.2 Full size inspection

 The full size inspection must always be performed by the manufacturer. In inspection, only the
size necessary for the product must be checked.
 Inspect the side of the upper frame, gas ducts and hopper connection by using a spine batten.
 Check the horizontal and vertical braces referring to the original drawing and check if there is
any part which is unsuitable for assembly or part which cannot be bolted.
 Put the reference and center line in the templates and spine batten and make sure they are in
accord with each other.
Note:
Allowable tolerance of full size is ± 1.0 mm
(Between reference lines, between columns, between girders, diagonal line, template &
spine batten)

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5.3 Cutting inspection

Make sure each cut face made by cutting is not post-looking

Section Roughness Notch

Inside of groove 200S or less 2 mm or less
Free edge 100S or less 1 mm or less

5.4 Groove inspection

Make sure the joint profile of the welded part is normal.

Refer to the attached data1. “Accuracy of weld joint (groove)”

5.5 Dimensional inspection

Perform the dimensional inspection referring to the design / shop drawing and make sure the
dimensions are within the criteria shown below:
 The basic dimensional tolerance shall be in accordance with the product accuracy as mentioned
on material certificate.
 The detailed dimensional tolerance report and the measuring points of dimensions shall be in
accordance with fabricator standard Inspection report form.

5.6 Inspection of appearance (Visual inspection)

Check the appearance visually and make sure of the following points:
 There must be no poor-looking parts such as crack, mar, puncture, etc on the surface of material.
 Each cut face mustn’t be poor looking
 Each bolt hole must be normal, free of burred
 There must be no failure to work or mount
 There must be no sticking of mud, sand, heavy oil and fat

5.7 Visual inspection of welds

Check the welds visually to make sure they are within the criteria of acceptance refer to the design /
shop drawing of welding detail – data attachment 1.

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5.8 Painting inspection

Make sure of the following points
 The paint film thickness must be within the specified values when checked by the following
method.
 The paints used for the work must be those specified.
 The skipping No. and weight must be entered

Criteria Measuring frequency

(1) Average of measured values : (1) One point every area of 10 m2
More than 100% of standard value
(2) Minimum value : (2) Measured value of one point shall be the mean value
More than 80% of standard value of 3 points

Attached data 1. Accuracy of weld joint (groove)

Description Drawing Tolerance

(1) Clearance in fillet welding e<5mm

(e) However, when “e” surmounts 2
mm, increase the size by “e”. A
clearance exceeding2 mm mustn’t
be ranging an overall length.

(2) Clearance at lap joint 2.0 mm

(e)

(3) Clearance at backing metal 1.0 mm

(e)

(4) Discrepancy in groove t < 1.5 mm ± 1.5 mm

weldment 1.5 mm < t < 30 mm t/10
(e) t  30 mm ± 3.0 mm

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(5) Root gap (back chipping) a1  3.0 mm

(a1 & a2) a2  4.0 mm

(6) Root gap (with backing 0 + 5 mm

metal) (a)

(7) Root face a < 3 mm ± 1 mm

(a) a > 3 mm ± 2 mm

(8) Groove angle - 0° + 10°

(a)

Description Drawing Tolerance

(10) Web bend 1/150

(d/H, d/B)

(11) Hole pitch ± 2 mm

(P)

(12) Discrepancy between holes 1 mm

(d)

(13) Roughness of gas cut face

Inside of groove
Less than 200S

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Free edge
Less than 100S

(14) Notch depth as gas cut face

Inside of groove
Less than 2 mm

Free edge
Less than 2 mm

(15) Clearance between faces at

High strength bolt grip 1.0 mm (before tightening)
joints
(e)

(16) Length Unless otherwise specified in the

(L) inspection report and manufacture
drawing, the length (L) shall be as
follow.

Dimension (mm) Tolerance (mm) Dimension (mm)

Over 0 to 100 include ±2 Over 1600 to 3200 include

Over 100 to 200 include ± 2.5 Over 3200 to 6400 include
Over 200 to 400 include ±3 Over 6400 to 12500 include
Over 400 to 800 include ±4 Over 12500 to 25000 include
Over 800 to 1600 include ±5

Attached data 2. Product accuracy (1/2)

Description Drawing Tolerance

(1) Bolt pitch ± 3 mm

(L)

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(2) Bend 1/1000

(d/L)

(3) Height H < 400 mm ± 2 mm

(H) 400 mm < H < 1000 mm ± H/200
H > 1000 mm ± 5 mm

(4) Width ± 3 mm
(B)

(5) Torsion 20°

(B)

(6) Tilt of flange B < 200 mm B/100

(d) B > 200 mm 2 mm

(7) Bend of flange b < 100 mm b/100

(d) b > 100 mm ± 1mm

(8) Misalignment center 2 mm

(d)

(9) Angle at joint 1/500

(d/L)

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Attached data 3
Accuracy of Weldment

Description Drawing Tolerance

(1) Size of fillet welding +3

(S) e
-0
However, for less than 10% of the
length, -0.1 S is accepted.
(2) Throat of fillet weld +
(a) e
-0
This is the same as in - Para. Of
reinforcement. However, for less
than 10% of the weld length, -
0.07S is accepted.
(3) Reinforcement of fillet weld 0.1 S + 1 mm
(c) -0

(4) Reinforcement of butt weld Max + 4 mm

(c) Min+ 0.5 mm

(5) Undercut Undercut depth Less than 0.05 t

and 0.5 mm

(6) Unevenness of bead surface The unevenness of bead surface

shall be less than 2.5mm at a range
of 150 mm of weld length. The
irregularity of bead width shall be
within 5 mm at a range of 150 mm
of weld length.

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6. CAUTIONS IN DELIVERING PRODUCTS

6.1 Entry of shipping no.

6.1.1 Shipping No.

(1) The shipping No. Shall be according to the bill of quantity issued from the Design Dept.

6.1.2 Entering procedure

(1) The entering position shall in principle be at an upper right corner facing the products
surface.
(2) For such long materials as a column, brace, etc. the number must be put on the upper
positions viewed from the structures.
(The number are not entered on the concave side of H and U steels)

(3) For the piping, put the number on the upstream side of fluid
(4) Pack small parts (bolts, nuts, packings, etc.) in bags or bind them and attach a tag in
which the shipping No. has been put to each bag or bound thing.
(5) How to enter

a. Casing & girder

….Shipping No or DWG No. &

Product No.
….Name of product
….Quantity
….Product weight (enter only when
the weight of one lot exceeds 1 to

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b. Brace & Piping

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