Oil Tank 750 m3

PROCEDURE FOR FABRICATION DOCUMENT NO.
:
OIL TANK 750 M3 P-T3109-CONS-044
PLTU 1 3X330 MW POWER PLANT ISSUED DATE :
INDRAMAYU – WEST JAVA July ’ 04 2009
UNIT ISSUING: APPROVED BY : Site Manager PAGE REVISION
Construction 1 of 15 0
PROCEDURE FOR FABRICATION OIL TANK 750 M3

PLTU 1 3X330 MW POWER PLANT
INDRAMAYU - WEST JAVA
DOCUMENT NO: P-T3109-CONS-044
ORIGINATED BY REVIEWED BY APPROVED DISTRIBUTION

BY
- SDCC : Original
- CNEEC : Copy
- Originator: Copy
Mech. Engineer Area Manager SMR Site Manager -WBS/Sect : Copy
REV ISSUED EFFECTIVE BRIEF OF REVISION.

NO. DATE. DATE.
00
TABLE of CONTENT
PROCEDURE FOR FABRICATION DOCUMENT NO. :
No Description Page
COVER 1 OF 15
TABLE of CONTENT 2 OF 15
1.0 TITLE 3 OF 15
2.0 SCOPE OF APLICATION 3 OF 15
3.0 OBJECTIVE 3 OF 15
4.0 REFERENCE 3 OF 15
5.0 DESCRIPTION OF PROCEDURE 3 OF 15
6.0 RELATED DOCUMENT 4 OF 15
7.0 WELDING QUALIFICATION TEST 5 OF 15
8.0 SCOPE 5 OF 15
9.0 METHOD OF MARKING 6 OF 15
10.0 CUTTING INSPECTION 6 OF 15
11.0 DIMENSION INSPECTION 8 OF 15
12.0 FIT-UP INSPECTION 11 OF 15
13.0 VISUAL INSPECTION 12 OF 15
14.0 NONDESTRUCTIVE INSPECTION 13 OF 15
15.0 REPAIR BY WELD 14 OF 15
16.0 PAINTING INSPECTION 14 OF 15
17.0 SUBMITTAL OF INSPECTION AND TEST RECORDS 15 OF 15
1. TITLE
Precedure for fabrication of Oil tank for 3 x 330 MW Coal fired steam power
generation.
2. SCOPE OF APLICATION
This procedure describes the fabrication of Oil Tank set PLTU 1 West Java
( Indramayu ) – Indonesia.
In this connection, if any modification to this instruction it shall be carried out after
reviewed by the concern person.
3. OBJECTIVE
This procedure is to ensure that the fabrication of the oil tank set following the client
requirement, code and specification and to obtain good quality workmanship during the
installation works. And this is also as systematic guidance for concerned Supervisor or
Engineer to oil tank .
4. REFERENCE
4.1. SDCC-001, Guidelines for Establishing Project Procedure.
4.2. E03033-PR-3001, Construction Execution Plan.
4.3. MC-001, Material Receiving.
4.4. MC-003, Moving Storage Procedure.
4.5. Arrangement Drawing from Vendor.
5. DESCRIPTION OF PROCEDURES
5.1. Material
5.1.1. General
All materials required for completion of fabrication and ensure that
material to be procured in the field are as follows:
5.1.1.1 Old materials having any loss of effective thickness due to rust
shall not be used.
5.1.1.2. All distortion caused during transportation or handling shall be
corrected by approved method.
5.1.2. Delivery
5.1.2.1. Take delivery of equipment to be fabricated and inspect for
damage.
5.1.2.2. Complete a list of all materials delivered to site and provide
a copy to Client.
5.1.2.3. If following the delivery, equipment members are found to have
defect, bends from the required shape they shall be corrected
and repaired prior to erection.
5..1.2.4. Damage equipment members shall be reported, in writing to the
Client.
5.1.3. Handling
5.1.3.1. Any movement of material shall be under control of Material

Control Engineer at all times and reported to Client.
5.1.3.2. Unload and load trucks by using cranes or forklifts. Do not unload
materials by free fall from trailers or trucks.
5.1.3.3. To drag or tow material along the ground is prohibited.
5.1.3.4. Handle equipment elements and other materials by utilising tools
and equipment of adequate safe capacity.
5.1.3.5. Handle equipment elements using installed lifting hooks, if any or
other appropriate means.
5.1.4. Storage
5.1.4.1. Lay down area to be established with clear marking unit wise.
5.1.4.2. Storage areas are to be properly graded, flattened and made free
from water.
5.1.4.3. Secure all materials to prevent loss or damage.
5.1.4.4. Keeping all areas designated for storage in a clean, tidy and
orderly manner is mandatory. Easy access should be maintained
for handling, identification and inventory.
5.1.4.5. Separately store materials which have been found damage or
defective, such materials can be transported to site only after the
defect and /or the damage has been repaired or eliminated. Store
at designated location all items which can not be repaired.
5.1.4.6. Store materials according to respective item classification. Do not
store together different elements, sizes and shape.
5.1.4.7. Stack steel members on wooden planks, platforms, skids or other
supports and keep completely clear from the ground and water.
Do not store steel members on uneven supports.
5.1.4.8. Store materials in accordance with supplier’s recommendations
and in sheltered area, especially those materials which are
susceptible to deterioration.
5.1.4.9. High strength bolts, mild steel bolts and electrodes are to be
stored in watertight and dry place.
5.1.5. Protection
5.1.5.1. Use all means to protect steel members and packaged materials
from corrosion and deterioration.
5.1.5.2. Protect the work and materials from damage by all other trades.
6. RELATED DOCUMENT
Applicable Law codes and Regulation
1) API 650 : Welded Steel Tanks for oil Storage

2) API 620-10 th Edition : Design and Construction of Lange Welded.
Low Pressure Storage Tanks
3) ASME Section IX,2001Ed : Qualification standard for welding and brazing
With 2003 Addenda procedure, welders, and welding Brazing operators

4) ASME Section V ,2001 Ed : Nondestructive examination
5) API Std 2000 Venting Atmospheric and low –pressure Storage Tanks
6) ASTM A36 Structural Steel
7) ASTM A283 Low and Intermediate Tensile Strength Carbon Steel Plates of
Structural Quality ( Grade “C’ only )
8) ASTM A285 Low and Intermediate Tensile Strength Steel Plates of Structural
Quality ( Grade “C” )
9) ASTM A204 TP304/316 Stainless Steel Plates
10) Occupational Safety and Health Act of 1970 ( OSHA )
11) Relevant ASTM Standards
12) Local ,state and National Codes
7. WELDING QUALIFICATION TEST
7.1 Welding procedure Qualification
The welding procedure specification(WPS) shall be supported by the records of

procedure Qualification test (PQR) that have been performed in accordance with
ASME Section IX.
7.2 . Welder Performance Qualification
1) The welders who weld pressure parts and non pressure parts joints such as all
permanent and temporary clips and lugs ,to pressure parts shall be qualified
in
accordance with ASME Section IX.
2) The list of qualified welder and previous welder’s records shall be submitted to
the purchaser’s inspector for review prior to commencement of welding works.
3) If new test for welders was taken the welder performance qualification test
shall be performed in accordance with the welders qualification test
procedure.
4) Welders shall be initially qualified by bend test or RT
8. SCOPE
The following materials shall be identified by the mill marking on actual materia And
heir material identification record shall be made.
1. Annular and bottom plates.

2. Roof plate
3. Manhole & Nozzle neck
4. Flange & Cover plate
5. Reinforcing pad plate

6. Top angle & shell stiffener
9. METHOD OF MARKING
1) During shop fabrication, in case the mill marking is unavoidably cut out or
the material is divided into two or more pieces .coded marking (CM) shall be
properly stamped or marked on each of the material before cutting.
2) .CM shall be done with LSD (low stress die stamp) or white color paint in
accordance with the requirements show in the following table and shall be
circled with paint to find out the location of them early.
Material Thickness ( T ) Method
T  6.35 mm LSD Note 1

White paint Black paint for
T  6.35 mm
( Note 1 ) Stainless steel
3). CM is retraceable marking for mill marking, which consists of tank number,
part or shell course
number serial number ,material spec, and original heat no ,or plate no.
4).CM shall be so located as to be plainly visible when CM disappears in shop
paint it shall be, re-marked on the painted surface of materials.
5). The location of coded marking is as follows.
Approx. 200 mm
inside
Heat No &
Coded Marking
Shell Plate
6). Coded marking and heat no with traceability shall be recorded.
10. CUTTING INSPECTION ( Edge preparation check)
1 The plate shall be cut by thermal means and the contamination such as oxide scale
slag which
would be adversely affected to the quality or strength of the weld shall be removed.
2 Plate edge shall be closely inspected by visual.
3 Uneven surface of plate edge shall be treated as follows :
d
d
A A
A- A’
Part Size of notch (mm) Treatment Remarks

d≤ 1.5. w ≤ 3 Use as it is
Roof face d 1.5. w 3 Weld repair and MT or (*1 )
PT
d≤ 0.5. w ≤ 1 Use as it is
d≤ 1.5. Smooth by grinder
Bevel 1 w ≤ 3
d 1.5. w 3 Weld repair and MT or ( *1 )
PT
Note:
( *1 ) Repair weld shall be performed by a qualified welder and approved welding
Procedure specification ( WPS )
4 . If the tolerances of bevel are not specified in the drawing they shall be as follows.
a a a
b b
a
Single –V Square-groove Double – V
Type of Tolerance
bevel a,a’ b (mm)
Square-groove ±2.5~ -
Single-V
±2.5~ ±1.5
Double-V
11. DIMENSION INSPECTION
11.1 Shell Plate
1) The dimension inspection of shell plates shall be performed prior to bending. The
dimension tolerances of shell are as follows
A E B
Measurement items Tolerance mm
Width (AC,BD,EF ) ±2
Length (AB, CD) `± 2
Diagonal (AD,BC ) 3 Max
C F D
2) The curvature of shell plate shall be checked by a curvature gauge with the tank
radius as shown below. The deviation (C1, C2, E) of curvature on the inside surface
of shell plate shall be 3 mm and less.
C1
C2
E
Gauge 1.5 m
11.2 Nozzle and manhole attached to shell plate
The dimensional tolerance of nozzle and manhole attached to shell plate are as follow.
Items Measurement items Tolerance ( mm)

Projection ( C ) ± 5~
Inclination of ± 0.5~
Flange face to neck ( D)
Nozzle
Location ( H ) ± 10
And ( L) ± 10
Manhole Projection ( C ) ± 10
Inclination of ± 1.0~
Flange face to neck ( D)
O.D of manhole neck ( A ) ±3
O.D of flange ( B ) ±4
Thickness of plate flange -0 ,+3
Location ( H,L ) ± 20
D B
C
A
H
11.3 Reinforcing pad for nozzle and manhole
The allowable tolerance of reinforcing pad is as follows
Measurement
Tolerance ( mm)
items
d 1 ,d2 ` 1.5
D1 ,D2 ` 3.0
d1 D1
d2
D2
11.4 Top angle and shell stiffener
The curvature of top angle and shell stiffener shall be checked by means of placing
them along the marked line of tank radius on platform.
The allowable tolerance are as follows.
Measurement items Tolerance ( mm )
Length ( L ) ` 3.0 / 6 m
Warp distortion( S ) 1.15% of length ( Max .9.0
mm)
Twist distortion( S ) Max .5.0 mm
Curvature ( E) ` 3.0 / 6 m
S
S
Warp Twist
11.5 ROOF PLATE
The dimensional tolerances of roof are as follows.
Measurement items Tolerance ( mm

Width (AC , BD ) -0 , +10

Length ( AB , CD ) -0 , +10
Diagonal ( AD – BC ) M ax 5.0
11.6 Other tank accessories

The dimensional tolerance of other tank accessories are in accordance with
engineering drawing and design specification
12. FIT-UP INSPECTION
1. The parts to be welded shall be cleaned out and free from scale ,rust , oil and other
deleterious foreign material for a distance of at least 13 mm from the welding joint
preparation
2. Alignment of section of edges to be butt welded shall be in such that the maximum
offset is not greater than in the allowed tolerances listed in the table below and the
edges of butt joints shall be welding so that the alignments are not exceed in the
completed joint.
2.1). Nozzle & Manhole
Direction of Joints Thickness Tolerance, mm
Girth Butt
Longitudinal butt All + 1.5
Branch connection
2.3) Plate
Direction of Joints Thickness( mm ) Tolerance, mm
Vertical T ≤ 16.0 1.5

T > 16.0 0.1 X T ( max . 3.0 )

T < 8.0 1.5
Horizontal
T ≥ 8.0 0.2 X T ( MAX. 3.0 )
Note:
The thickness “ T “ is the nominal thickness of the thinner section at the joints
3. The configuration and dimension of joints to be welded shall be checked with the
drawing or welding procedure specification.
Unless specified in the drawing ,allowable tolerances shall be as follows:
± 5.0° ± 2.5°
± 1.5 ±1.5
± 2.0 ±2.0
13. VISUAL INSPECTION
13.1. Regardless of any others method of inspection used , all weld shall be subjected
to v Visual inspection and they shall meet the following requirements.
1).The welded parts shall be free from crack, overlap , convex , ripples, slag and
others deleterious defects and undercut shall not exceed 0.4 mm in depth
2).The reinforcement of the welds on all butt joints on each side of the plate shall not
exceed the following thickness
Nominal plate MAX. Reinforcement thickness , mm

Thickness , mm
Vertical joints Horizontal joints
T ≤ 13.0 ¼t ¼t
13.0 < T ≤ 25.0 3.0 ¼t
25.0 < T 1/8 t 1/8 t
3). Complete fusion and required penetration exists at the joint between the weld
metal and the Base metal.
13.2. Welded that fail to meet the visual inspection criteria given item 9.1 shall be repair
before Hydrostatic testing in accordance with the following.
1) Any defects shall be removed by mechanical means or thermal gouging processes

2) Repair welding is required, if the resulting thickness is less than the minimum
required for design / hydrostatic test conditions
3) All defects in areas thicker than the minimum shall be feathered to at least a 4.1
taper .Minimum thickness shall be confirmed after grinding
4) The repair weld shall be visually examined and liquid penetrant test
13.3. The gasket contact surface of the flange shall be visually checked to ensure
cleanliness and is free from any surface defect.
13.4. All the flange surface shall be protected from mechanical damage an the time.
14. NONDESTRUCTIVE EXAMINATION ( NDE )
14.1 The extent of NDE is as show in the following table and shall be carried out in
accordance with the NDE procedure.
14.2 Final NDE ( MT ) for butt weld joint shall be carried out after PWHT ( if any )
Joint Examination method Remarks

No Weld of Type
BG CW
Longitudinal seam of
shell, 100 %
1 Butt PT N/A
Manhole (Site only),
Nozzle neck *
Circumferential seam of Fillet
N/A MT **
flange to shell nozzle
2
and Butt
N/A N/A
manhole
Shell to bottom plate Fillet
3 N/A N/A If Any
welding
Repaired area where MT
4 Surfaced N/A
jigs have been removed (or PT )
5 Bottom Sump Fillet N/A N/A If Any
Abbreviation
CW : Completed Weld N/A : Not Applicable
RT : Radiographic Examination PT : Liquid Penetrate

Examination
MT : Magnetic particle examination QT : Oil Penetrate test
BG : Back Gouging WT ; Water Fill Test
* Made from rolled.

** PT may be substituted if MT is not applicable on the joint configuration.
15. REPAIR BY WELD
15.1 When defect appears to be removed , repair weld shall be made accordance with
the approved welding procedure specification and welding repair procedure
Repaired area shall be re-examined by the same method originally taken
15.2 Defects in weld shall be repaired by chipping , grinding or gouging out the defects
from one side or both sides of the joint as required and welding
15.3 When the defect found is a major defect, a detailed defect map and the weld repair
procedure shall be issued for approval. It shall describe the work step of the repair,
applicable NDE and its extend before and after the weld repair, together with WPS &
PQR intended to use. The repair work of any major defect shall not be performed
without any approval.
16. PAINTING INSPECTION
16.1 Surface preparation

1). Before blasting surface preparation ,surface condition shall be visually confirmed
spatter, sharp edge treatment, grease ,oil ,etc shall not be detected and flange
face as well as machined face should be protected.
2). Immediately after completion of surface preparation the surface shall be visually
checked and confirmed whether it meets the required cleanliness & anchor
profile specified in the painting procedure.
3) The prime coat of paint shall be applied within 2 hours after completion of surface
preparation.
16.2 Painting
1) Before any painting works the brand name and RAL Code no of paint material
shall be checked against the paint specification.
2). NO painting works shall be done in the following weather condition of the working
area.
(1). Rain, snow ,fog or mist
(2). When the relative humidity is greater than 85%
(3). Dust effects adversely due to high wind
3) At each thickness, step of painting work , number and dry film thickness of coats
shall be confirmed whether , meets the requirement specified in the painting
procedure.
4) Coating system is cured as specified by the paint manufacturer’s printed
instruction for recoat intervals.
5) The painted surface shall be visually inspected for defects such as inadequate
curing, runs and lack of adhesion, pin hole ,mechanical damage etc .all repairs
should be done for defects.
6) After completion of painting work, the final color shall be visually checked with the
standard of color, whether it meets the specified one.
7) The coating work indicating defects, improper application, runs ,sags, damages
excessive repairs, incomplete curing or excessive thickness is subject to
rejection.
17. SUBMITTAL OF INSPECTION AND TEST RECORDS
The results of inspection and test shall be properly recorded just after the inspection
and test the following inspection and test record shall be submitted to the purchaser
after final inspection.
1).Mill certificates
2).Nondestructive examination report.
3).Dimensional inspection record.
4).Painting inspection record.

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What is the scope of this procedure?

What is the scope of this procedure?

What inspections will be conducted during fabrication?

What inspections will be conducted during fabrication?

PROCEDURE FOR FABRICATION DOCUMENT NO.

PROCEDURE FOR FABRICATION OIL TANK 750 M3

ORIGINATED BY REVIEWED BY APPROVED DISTRIBUTION

REV ISSUED EFFECTIVE BRIEF OF REVISION.

2.0 SCOPE OF APLICATION 3 OF 15

5.0 DESCRIPTION OF PROCEDURE 3 OF 15

6.0 RELATED DOCUMENT 4 OF 15

7.0 WELDING QUALIFICATION TEST 5 OF 15

9.0 METHOD OF MARKING 6 OF 15

10.0 CUTTING INSPECTION 6 OF 15

11.0 DIMENSION INSPECTION 8 OF 15

12.0 FIT-UP INSPECTION 11 OF 15

13.0 VISUAL INSPECTION 12 OF 15

14.0 NONDESTRUCTIVE INSPECTION 13 OF 15

15.0 REPAIR BY WELD 14 OF 15

16.0 PAINTING INSPECTION 14 OF 15

17.0 SUBMITTAL OF INSPECTION AND TEST RECORDS 15 OF 15

5.1.3.1. Any movement of material shall be under control of Material

1) API 650 : Welded Steel Tanks for oil Storage

With 2003 Addenda procedure, welders, and welding Brazing operators

7. WELDING QUALIFICATION TEST

7.1 Welding procedure Qualification

The welding procedure specification(WPS) shall be supported by the records of

7.2 . Welder Performance Qualification

4) Welders shall be initially qualified by bend test or RT

1. Annular and bottom plates.

5. Reinforcing pad plate

Material Thickness ( T ) Method

T  6.35 mm LSD Note 1

6). Coded marking and heat no with traceability shall be recorded.

10. CUTTING INSPECTION ( Edge preparation check)

2 Plate edge shall be closely inspected by visual.

3 Uneven surface of plate edge shall be treated as follows :

Part Size of notch (mm) Treatment Remarks

bevel a,a’ b (mm)

11. DIMENSION INSPECTION

11.1 Shell Plate

11.2 Nozzle and manhole attached to shell plate

Items Measurement items Tolerance ( mm)

11.3 Reinforcing pad for nozzle and manhole

The allowable tolerance of reinforcing pad is as follows

11.4 Top angle and shell stiffener

The allowable tolerance are as follows.

Measurement items Tolerance ( mm )

11.5 ROOF PLATE

The dimensional tolerances of roof are as follows.

Measurement items Tolerance ( mm

Width (AC , BD ) -0 , +10

11.6 Other tank accessories

Direction of Joints Thickness Tolerance, mm

Direction of Joints Thickness( mm ) Tolerance, mm

Vertical T ≤ 16.0 1.5

T > 16.0 0.1 X T ( max . 3.0 )

Nominal plate MAX. Reinforcement thickness , mm

Vertical joints Horizontal joints

1) Any defects shall be removed by mechanical means or thermal gouging processes