Fabrication Procedure

Doc No. 010.23-TK-SOP-03

Job No. 010/FAB-PTT/I/23
Rev. 0

Note:

This Standard Operational Procedure is a general methodology, the implementation according to the
agreed as state on scope of work

Rev Date Description Prep’d Check’d Approv’d

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Contents
1. GENERAL .................................................................................................................................................. 3
2. DEFINITION OF TERMS ............................................................................................................................. 3
3. SCOPE ...................................................................................................................................................... 3
4. STANDARDS ............................................................................................................................................. 3
APPLICABLE CODE AND STANDARD ................................................................................................................ 3
5. DRAWING ................................................................................................................................................. 3
6. MATERIAL RECEIVING, IDENTIFICATION, AND TRACEABILITY .................................................................. 3
7. WELDING .................................................................................................................................................. 5
8. INSPECTION ............................................................................................................................................. 5
A) VISUAL TEST AND DIMENSIONAL TEST .................................................................................................... 5
B) LIQUID PENETRANT TEST ......................................................................................................................... 5
C) RADIOGRAPHY TEST................................................................................................................................. 6
D) PNEUMATIC LEAK TEST ........................................................................................................................ 6
E) VACUUM BOX TEST................................................................................................................................... 6
9. STRESS RELIEVING / POST WELD HEAT TREATMENT (PWHT) ................................................................ 6
10. SHOP FABRICATION.............................................................................................................................. 6
a. Plate ......................................................................................................................................................... 8
b. Bottom Plate, Annular Plate, and Roof Plate ......................................................................................... 12
c. Manhole & Nozzle .................................................................................................................................. 13
d. Shell Plate with Manhole, Nozzle & Clean Out Nozzle ........................................................................... 16
e. Reinforcing Plate .................................................................................................................................... 16
f. Roof Structure ........................................................................................................................................ 17
11. DIMENSIONAL TOLERANCES FOR PRIMARY COMPONENTS .............................................................. 19
12. BLASTING AND PAINTING ................................................................................................................... 21
13. PROTECTIVE OF FABRICATED MATERIAL............................................................................................ 22
A. PROTECTIVE FOR SITE WELDING ....................................................................................................... 22
B. PROTECTIVE FOR PRESERVATION AND DELIVERY ................................................................................. 23

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1. GENERAL
This procedure is intended to be used as reference in application of Shop Fabrication of Storage
Tank, which are fabricated by PT. Sarana Remaja Mandiri.

2. DEFINITION OF TERMS
Terms Definition
PROJECT Pro Tank Expansion Project Phase 3

OWNER PT. Pro Tank Treminal

CONTRACTOR PT. Sarana Remaja Mandiri

3. SCOPE
The Shop Fabrication materials of Storage Tank, in workshop of PT. Sarana Remaja Mandiri

4. STANDARDS

Applicable Code and Standard

NO TITLE REFERENCE DOCUMENT

API Standard 650 12th Edition,
1 Welded Tanks for Oil Storage
Addendum 1,2,3
2 Boiler & Pressure Vessel Code - Materials ASME Section II
Boiler & Pressure Vessel Code - Non-Destructive
3 ASME Section V
Examination
Boiler & Pressure Vessel Code - Welding and
4 ASME Section IX
Brazing Procedure

5. DRAWING
Basically all drawings which are used in performing the work shall be the latest revision of
fabrication drawing which have been approved by Contractor, or the status of drawing shall be
“Approved for Construction” (AFC).

6. MATERIAL RECEIVING, IDENTIFICATION, AND TRACEABILITY

Before performing the job, all purchased / supplied materials shall be controlled by the Material
Control and Quality Control (QC) person, to ensure that the material meet the code and standard.

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QC personnel shall ensure and record all identification marking, which consists of material
specification, item number, heat number, and the other as per Doc. No. 26071-100-3PS-MTF5-
00001. If the markings of material identification lost because of next manufacturing process, the
marking shall / will be re-transferred by the QC personnel with following Doc. No. 26071-100-3PS-
MTF5-00001 for method of marking.
All required documents shall be attached as additional verification namely:
 Purchase Order/PO
 Material Certificate
Material Control, shall propose Request for Inspection (RFI) to the QA/QC. QA/QC will notified to
Tank Inspector from representative Contractor and Company to observe together as needed. All
inspections shall be recorded by the material control person and approved by quality control
person.
Any defect and/or nonconformance shall be reported, kept apartly and reported as Non
Conformance Report (NCR).
Material Control Personnel, finally shall publish a report to actual materials which is now in and
accepted periodical.
For stamp marking and transfer identification, marking personnel shall assign all identification
marking, which consists of material specification, item number, heat number or plate number for all
parts. If the markings of material identification be lost because of next manufacturing process, the
marking shall be re-transferred by the marking personnel.
Where the service conditions prohibit die stamping for material identification and when so specified
by Owner or for the piece of material under ¼ inch (6 mm) in thickness, the marking shall be
marked with steel marker so that each piece of material will be positively identified. The quality
control person shall be responsible for verification of the material identification marking transfer
which was made by the shop personnel.
The marking personnel shall lay out the item or part to be cut on the intended material and stamp
the applicable marking on the each item or part by using the blunt-nose die stamps accordance with
cutting plan and applicable drawing. The depth of the stamping should be approximately 0.2 mm or
less. All identification material and part shall be marked completely and the quality control person
shall be inspected before cutting to be done.

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7. WELDING
WPS (Welding Procedure Specification) & PQR (Procedure Qualification Record), shall be
performed in accordance with ASME Sec-IX standard and the WPQT (Welder Performance
Qualification Test), shall be performed and certified by MIGAS
All welding application and / or tack weld to the base material (permanent materials for tank and
also on the supporting equipments for fabrication and erection (temporary attachment), shall be
conformed with (WPS), and performed by qualified welder. Temporary attachment materials shall
be same with the base material, and after done shall be released and grinded smoothly and
entirely.
If condition hopped, process during release and temporary attachment welding, then pick up
welding shall be performed on ‘under-cut’ area using appropriate welding electrode. Ex under-cut
area that had been repaired, need to be tested by Penetrant Test (PT), in order to know the
possibility of cracks happened on the surface.
Welding repair on the joint-weld can be done by method of chipping, gouging, or grinding, to clean
and eliminate welding defects. Re-weld shall be performed base on approved WPS, and approved
repair procedure according to Inspector’s guidance and approval.
Repair on the same area can be performed twice only. If afterwards there is still any fault/defect
found and required repair then must be agreed or permitted by the Contractor and Company.

8. INSPECTION
Inspection activities are performed in accordance with approved Inspection and Test Plan (ITP),
this inspection activities cover :

a) Visual Test and Dimensional Test

The visual examination procedure shall be in accordance with the requirements and method
specified in API Standard 650 Para 8.5, ASME Code Section V, Article 9 and this specification.
Surface of all finished weld shall be visually inspected.
(See Visual and Dimensional Procedure, Doc No. 26071-203-V42A-MTF5-50016)

b) Liquid Penetrant Test

The examination procedure shall be in accordance with requirements and methods specified in
API Standard 650 Para 8.4, ASME Code, Section V, Article 6 and this specification. Base material
1 (one) inch on each side of the weld shall also include in the examination of weld. (See NDT
Procedure, Doc No. 26071-203-V42A-MTF5-50012)

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c) Radiography Test
The Examination procedure shall be in accordance with the requirements and methods specified
in API Standard 650 Para 8.1, ASME Code, Section V, Article 2 and this specification
According to API STANDARD 650 para 8.1.5, the acceptability of weld examined shall be judged
by standard of Paragraph UW – 51 (b) in Section VIII of ASME Code.
(See NDT Procedure, Doc No. 26071-203-V42A-MTF5-50012)

d) Pneumatic Leak Test

The pneumatic leak examination procedure and acceptance criteria described in Pneumatic Test
Procedure, Doc No. 26071-203-V42A-MTF5-50022

e) Vacuum Box Test

The vacuum Box examination procedure and acceptance criteria described in Vacum Box Test
Procedure, Doc No. 26071-203-V42A-MTF5-50010
Welding traceability record will be provided due to welding for fabrication of Manhole and Clean
Out Door. See figure A below for example.

9. STRESS RELIEVING / POST WELD HEAT TREATMENT (PWHT)

If Stress Relieving (PWHT) is required by API 650 Standard, Para. 5.7.4.1-5, with concern to
Material Group Number and/or the Tank datasheet, it shall be carried out in accordance with the
Post Weld Heat Treatment requirements therein and of ASME Section VIII Division 1 UCS-56.
(See Heat Treatment / PWHT Procedure, Doc No. 26071-203-V42A-MTF5-50019)

10. SHOP FABRICATION

Basically Fabrication Process in work shop, include process: marking, cutting, beveling, rolling to
tank materials include : Shell plate, Bottom Plate, Roof Plate, Spiral stairway, Nozzle, Manhole,
and other tank accessories.
In general, the fabrication process can be described according to the flow process chart below

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Fabrication Flow Process Chart RECEIVING MATERIAL

INSPECTION
NO REJECT
 Traceability
RECHECK
 Dimensional
 Visual

YES
PLATE NON PLATE

 Marking for Layout  Marking

 Cutting Plan  Transfer Identification
 Transfer Identification

INSPECTION NO
REJECT
INSPECTION NO  Identification REPAIR
REJECT
 Identification REPAIR  Dimensional
 Dimensional

YES
YES
 Cutting, Grinding
 Cutting  Beveling (Pipe / Nozzle Neck)
 Beveling (Shell, Annular)
 Grinding (Shell, Roof, Bottom/Annular)
 Bending / Rolling (Shell, Nozzle Neck)

 Fit-Up (Tack weld)

 Sub Assembly (Nozzle, MH)

INSPECTION NO
REJECT
 Visual REPAIR
 Dimensional
INSPECTION NO
REJECT
 Visual REPAIR
 Dimensional
YES

PREPARE FOR YES

BLASTING & PAINTING
 Welding
(Refer to WPS & Weld Map)

INSPECTION NO
REJECT
 Visual REPAIR
BLASTING & PAINTING  NDE

YES
INSPECTION NO
REJECT
 Visual
REPAIR
 DFT

YES

PACKING & TRANSPORT

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a. Plate
- Shell Plate : Marking →Cutting →Beveling → Rolling
Can be briefly describe as follows (see sketch No.1)
 Place on a plate in the flat area/or cutting table that has been provided.
 Check perpendicularities on all four side of the plate. If there is two sides has
perpendicular, then do the cutting only on the two sides. And if there is no
perpendicularities precisely between the sides, then do the cutting on the all
four sides. In generally, the cutting is done on all four sides. And in the
following sketch is described cutting on all four sides.
 Perform marking on all four sides, with a row make a line marking on the side,
namely (for example) : L1’/L2’/W1’ and W2’ (cutting line), where L1,L2,W1,W2,
is outer edge of the plate line
 Do checking of the perpendicularities of cutting line by measuring the diagonal
length in the four corners of the area. The diagonal length should be the same.
So it is mean that the sides have mutually perpendicular and rectangular,
according to the size within the working drawings.
 Perform cutting process, right at the position of marking (marking line), and the
direction of cutting (cutting direction) as in sketch no.1. Care has to be taken to
the cutting sequence and cutting direction, as much to reduce and minimize
the plate deformation due to heat in the cutting process.
 Make cuts perpendicular first, and then angled cutting (bevel), on the top side
and bottom side, see sketch No.2
 Before cutting: L1≠L2 and W1≠W2, and after cutting should be obtained:
L1”=L2” and W1”=W2’
 If the cutting process is conducted by oxy acetylene or flame cutting, the edge
surface shall be ground back 1.5 mm in order to remove all oxidized scales
and hard spot

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Sketch: No.: 1
L1

L1”

W1”

W1 W2

W2”

L2”

L2

CUTTING LINES CUTTING DIRECTION END SIDE OF PLATE

L1 ≠ L2 , W1 ≠ W2 L1” = L2” , W1” = W2”

Before Cutting After cutting Process

Cutting Process

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Sketch No.: 2

2 1 1st Cutting : Perpendicular

3 Cutting

2nd: Angled Cutting

3rd : Angled Cutting

- Plate Rolling
After completion of the cutting process, some of the plate then will be performed
to bend with a rolling process. The plate will be rolled until reaches a certain
radius according to the drawing (for shell plate of the tank, it means the inside
diameter). Generally for tank with diameter more than 50Mtr and thickness of
plate less then 10mm, some time it is no need to bend.
The rolling process as follow: (see sketch No.3)
 Place the plate on the rolling machine table that has been equipped. Check
once again and make sure that the face to be rolled are in correct side (in-side
or out-side face and so to the bevelling shape meet to the drawing).
 Perform the rolling process step by step, in a few times till reaching the
desired radius. Please note that rolling radius not too large (over roll), because
this condition may make a difficulties when the plate are fitted-out during
installation works.
 Checking the radius by using a measuring board radius (sweep board), which
has been provided, (see sketch No.4)
 The thickness of shell shall be inspected after performing of rolling
 When finished rolling process, the rolled plate should be storage in the skid
shape in accordance with the form radius. This is to avoid any changing of
radius during storage period or during transportation. (see sketch No.5).
 Prior to delivery, or during placed in the workshop, the bevel edge shall be
protected by masking tape or by paint to avoid corrosion on the bevel edge.

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Sketch No.3
BENDING / ROLLING PLATE

SWEEP BOARD
BENDING ROLLER

Sketch No.4 SWEEP BOARD

Sketch No.5

TEMPORARY STORAGE AFTER BENDING

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b. Bottom Plate, Annular Plate, and Roof Plate

On the bottom plate, annular plate and roof plate it’s no need to fabricated (see the
drawing), and usually the sketches plate (shape plate) cutting process can be done at
shop, and moreover can be done directly in parallel during erection stage for roof
plate. If cutting process of bottom / annular / roof plate carried out on the erection
stage, the dimension of sketches plate is fitted as actual dimension and if the sketch
plate are cutting on shop, make sure that the dimension are according to the drawing
to avoid any mistake, and if necessary, exceeded slightly (+ / - 1 ") in anticipation of
the change during installation.
Fabrication Process of Bottom, Annular and Roof Plate include : Marking →Cutting
Some of the plate typical shape(s), as follows:

Rectangular and Sketches Shaped Plate (Sketch No.8)

Sketch No.: 8
L

L1 L2

Sketches Plate Sketches Plate

W

To be keep/reserve

Sketches Plate

Annular / BottomSketch

To be keep/reserve

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To be keep/reserve

Roof Sketch

Roof Sketch

L = Total Length of Plate W = Wide of Plate

L1,L2, L3 = Length of Sketches W1 = Wide of Sketches

Plate
R = Radius of Cutting Sketches

c. Manhole & Nozzle

i. Manhole shall include neck, flange and davit pipe
 Fabrication Manhole Neck from plate: Marking → Cutting → Rolling →
Welding → NDE as follows: (see sketch No.9).
 Fabrication Manhole Davit pipe: Marking → Cutting → bending

Sketch No.9

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ii. Fabrication : Flange Manhole ( see sktech No.10)

Fabrication of Flange Manhole are include : Marking → Cutting → machining &
Drilling

Sketch No. : 10

Waste

L = Length of Plate Manhole Flange

W = wide of Plate

iii. Asembling of manhole Neck to the manhole flange , and then weld it together (see
sketch No.11)

Sketch No.11

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iv. Fabrication of Manhole Cover (see sketch No.12)

Fabrication of Manhole Cover are include : Marking → Cutting → drilling

Sketch No.12 L

L = Length of Plate Waste

W = Wide of Plate Manhole Cover

v. Assembling of Manhole parts form Neck + Flange and Cover (see sketch No.13).
After manhole parts neck + flange are fitted and welded, and then the pace of
flange are to be machined with certain roughness as required (according to
drawing).and so to the manhole cover plate especially at contacted face area.
And next to the manhole + Neck Neck unit is assembling with its cover, and then made the
bolt holes.

Manhole Cover

Sketch No.13
Hole (drilling)

Manhole Flange

Manhole Neck

Manhole Cover

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d. Shell Plate with Manhole, Nozzle & Clean Out Nozzle

Opening on the shell plate (if PWHT are required)
According to Section 9 in this procedure, all the openings in the shell plate in the
form of manhole, nozzle and clean out Nozzle. In this case for the shell plate that
needed to PWHT, must be fabricated in complete set with the shell plate, (see
sketch No.14).

Sketch No.14

Shell Plate Course #1

T > 25 mm

Manhole
Nozzle

Clean-Out Door

e. Reinforcing Plate
Fabrication of reinforcing plate are include: Marking → Cutting → and Rolling (see
sketch No. 15)

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Sketch No.15
L

L = Length of Plate
Reinforcing Plate
W = Wide of Plate Waste

f. Roof Structure
Fabrication of roof structure are include : Marking → Cutting → Rolling, welding and
Drilling (see sketch No. 16)

Sketch No.16 Gusset/Rib

Center drums
s

Plate

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x Center drums

Channel/Profile
For Rafter

ØDia
PIPE COLOUMN .

Center drums

Rafter

Roof Structure Assembly

Pipe Column

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11. DIMENSIONAL TOLERANCES FOR PRIMARY COMPONENTS

According to Manufacturer’s Standard, API Standard 650, Paragraph. 7.5 and Project
Specification for Atmospheric Storage tank (paragraph 11.4) the dimensional tolerances for
fabrication work shall be apply:

a. Dimension After Cutting

Dimensions Tolerances

Width ± 1.5 mm

Length ± 2.0 mm

Difference in Diagonals ± 3.0 mm

Bottom annular plates after cutting

Wind Girder (formed plate section type)

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b. Plate edge after beveling

c. Curvature after bending to specified radius

d. Top angel and shell stiffeners

Top angle and shell stiffeners of structural section after bending to specified radius And
the folowing tolerances are based on 6-meters length.

e. Nozzles assembly

Item Tolerances

Specified Projection from outside of tank shell to flange face ± 5 mm

Elevation of Sshell Nozzle or Radial Location of a Roof Nozzle ± 6 mm

Flange tilt in any plane, measure on the flange face (NPS >12”) ±1/2 mm

Flange tilt in any plane, measure on the flange face (NPS ≤12”) ±3 mm

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Flange bolt hole orientation ± 3 mm

f. Shell Manholes assembly

Item Tolerance

Specified Projection from outside of tank shell to flange face ± 13 mm

Elevation ang angular location ± 13 mm

Flange tilt in any plane, measure across the flange diameter ±13 mm

O.D. of Flange ± 4 mm

Thickness of Flange - 0 mm, +3.0 mm

O.D. of manhole Neck ± 6.0 mm

12. BLASTING AND PAINTING

Painting activities shall be conducted in accordance with approved Inspection and Test Plan
(ITP), Doc No. 26071-203-V42A-MTF5-50004 and approved Sand Blasting & Painting
Procedure, Doc No. 26071-203-V42A-MTF5-50003

All equipment surface that require painting shall shop painted before delivery to site. All
surfaces, part and equipment as bolt threads, flange faces, etc should be protected before
shipment. Surface requiring field welding work (especially surface of bevel), have to free from
priming before delivery to site. And the surface requiring insulated, may be pre primer with the
primer paint before delivery to site.

All flux, welding spatter and arc strike shall be removed and the affected area ground smooth
with a grinder.
Rough weld, under cut, pin holes, and other irregularities shall be repaired, corrected and
ground smooth.
Sharp edges, unless required for specified purposed shall be rounded off. All spent abrasive
material, dust, scale, etc shall be removed from all surface by brushing or blowing with clean,
dry compressed air and vacumming before the application of paint.

Blast cleaned surfaces shall be kept clean, free of moisture and other contaminants which may
be detrimental to the application of the paint.

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The primer, intermediate and finish coat shall be different colours, and painting repair shall be
conducted if the paint condition as follow:
- Paint thickness was not reaching the value required
- Any damage during handling, transportation and unloading to the site.
- And another defective of paint.

For above, re coating shall be done at the point of damage surface with extent to the 50 mm of
the damage point as the following:
- Check the damage point.
- Extent to the 50 mm of that damage.
- Cleaning those surfaces with power brush.
- Re coating again with brush at those surfaces after suitable time.

13. PROTECTIVE OF FABRICATED MATERIAL

a. Protective for Site Welding
Weld bevels for site welding of shell plate and annular plate after grinding off the Mill shall
be protect painted primer with "Weldable Paint" or cover along the side of the bevel using a
seal tape which can be removed during installation prior to blasting and painting.

Protective Coating
or Seal Tape

Protective Coating
or Seal Tape

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b. Protective for Preservation and delivery

All of the steel plates material shall be covered by tarpaulin, plastic sheet or container to
protected material during preservation and delivery to site.
For the shell plates that has been rolled, shall be supported by brace or skid according to
sketch no 5 above to keep the bending radius from deformation.

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