PT.

SANGGAR SARANA BAJA

JAKARTA - INDONESIA



  
 

  





 

  
 

 

 
 
 



 
 

 




















 
 


 

 

 





  

DOCUMENT TITLE :

FABRICATION PROCEDURE

FABRICATION PROCEDURE AT SHOP

23 Dec 2011



  



  

REV.

DESCRIPTION



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PREPARED
BY



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DATE

APPROVED
BY

DATE

PT. SANGGAR SARANA BAJA

______________________________________________________________________

FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
REV.
:!
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1. General
1.1. This procedure is applied to the shop fabrication of Storage Tank for South
Sumatra NGL Project to be constructed in Sungai Gerong and Prabumulih South
Sumatra Indonesia.
2. Related Documents
2.1 Applicable code and Standards
1. API 650-11th Edition 2007: Welded Steel Tank for Oil Storage
2. ASME Section IX: Qualification standard for welding and brazing procedure,
welders, brazes, and welding and brazing operators.
3. ASME Section V: Nondestructive Examination.
4. SSNP-GEN-MEC-SPC-0005 Spec. for Atmospheric Tank
2.2 Applicable Procedures
1. Welding Procedure Specification (WPS) with PQR
2. Inspection and Test Procedure
3. NDE Procedure
3. Material Control
3.1. The materials receiving inspection shall be finished before starting the
fabrication. Foreman shall check the inspection report received from QA
department.
3.2. Review of the material Identification Number with Mill Certificates and/or
material list shall be done before fabrication.
3.3. An adequate care shall be taken on during material handling and transportation
to avoid damage and deformation, and especially for stainless steel, to avoid
carbon contamination.
3.4. Visual inspection shall be made to ensure no injurious defect such as sharp
notch, scratch, crack, lamination on the surface and cut edge of plate.
4. Fabrication Control
4.1. All fabrication works in shop shall be performed in accordance with the latest
documents such as drawings, procedures and applicable specifications.
4.2. All materials to be used in this job shall comply with the material specifications
described in the drawings.
4.3. The production welding shall be performed in accordance with the approved
welding procedure specification (WPS) and by the qualified welders.

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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
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5. Sh op Fabrication
The fabrication shall be performed in accordance with approved drawings,
applicable code and standards.
5.1 Mark ing
1. Prior to marking, the material shall be checked for material specification,
overall dimension, thickness and identification mark.
2. Marking shall be done direct on the material based on cutting plan, and
fabrication drawing.
3. Where the material is to be divided into two or more pieces, the ID mark
shall be transferred. The transfer of mark shall be made after layout but
before cutting.
4. After marking the material, the dimension of marking, ID mark shall be
inspected.
5. Color code shall be done on separated piece to classify the grade of
material before cutting.
5.2 Mark ing meth od
1. During shop fabrication, in case that the mill marking is unavoidably cut out
or the material is divided into two or more pieces, the original mill marking
of such material shall be properly re-stamped on the each piece after
marking out the cutting line for cutting and before commencement of
cutting.
2. The coded marking which consist of Tank No., Shell Course No. and Serial
No. as shown below shall be stamped or painted on each shell and annular
plates

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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
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3. Coded marking shall be done with Low Stress Die Stamp or White Color

Paint as shown in the following table.

Note: Black paint for stainless steel

4. Coded Marking and H eat No. shall be circled with white color paint to find
out the location of them easily.
5. The location of Coded Marking is as follows.

6. Coded Marking and H eat No. with traceability shall be recorded on the
cutting plan.
5.3 Cutting
1. Cutting of material and edge preparation shall be performed by thermal
cutting, machining and grinding etc. to obtain the specified shape. Prior to
cutting, the areas within 50mm of the cut shall be cleaned. The cut edge

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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
REV.
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______________________________________________________________________
shall be lightly ground back to remove all oxided and heat affected
materials.
2. In thermal cutting, scale and oxide shall be thoroughly removed by grinding.
The edge to be welded shall be uniform and smooth ground. In case of
stainless steel, iron contamination may initiate pitting attack during work, so
suitable precautions are necessary. The use of carbon steel wire brushes
and tool including grinding disc are prohibited. Austenitic stainless steel
brushed and tools shall be used.
3. Stainless steel (if any) has to be covered by paper to avoid carbon
contamination. The marking and color code shall be transferred.
5.4 Forming / Bending
Prior to bending, the surface of shell plate shall be cleaned by blower or
bloom to prevent damage during bending. Thin plate may use without rolled
condition according to discretion of supervisor.
1. The end portion of shell plate shall be formed to the required radius by
means of pressing prior to rolling.
2. For rolling of plates to cylindrical shape, bending roller shall be used. The
roller shall have smooth surface and shall not flaw the material. H ammering
shall not be used in the process of bending or forming the materials.
3. During after forming of plate, the radius or curvature shall be checked by
gauge plate.
5.5 W elding
1. Welding shall be carried out according to WPS and by qualified welders.
WPS & PQR shall be approved before commencement of welding.
2. The groove face and weld surface shall be free from oil, dust, scale, water
and other foreign materials and keep dry before welding.
3. Welder shall wear protective equipment to prevent skin and eye from
foreign substances during welding.
4. Welding sequence and control, fixture and strong back should be
considered before starting welding in order to prevent distortion of work.
5. The butt welding shall be slightly convex of uniform height, and have full
penetration. The butt joint shall be gouged or ground before welding for
reverse side.
6. Temporary attachment shall be removed by grinding method.
7. Visual inspection and NDE required.
5.6 Fabrication of comp onent

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FABRICATION PROCEDURE
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1) Sh ell Plate
Cutting for edge preparation shall be done with a flame planer, semiautomatic gas cutting machine or automatic beveling machine. Thermallycut surface edges shall be grinded up to 2mm to remove notches and
scale. The curvature of shell plate shall be performed by oil bandore and
checked by a curvature gage with the tank radius in accordance with
drawings, also the end parts of shell plate shall be carefully bended.
2) Annular Plate
Trimming of outer curvature and beveling for both ends of annular plate
shall be done with semi-automatic gas cutting machine. All damages
caused by gas cutting shall be smoothly finished by grinder.
3) Sh ell Stiffener & Top Ang le
The materials shall be cut and beveled after bending to the indicated
radius, and back plate on beveled will be attached for site welding.
4) Sh ell Plate w ith Noz z le and Manh ole
Shell opening shall be marked on the rolled shell plates and cut by semiautomatic gas cutting machine.
After tack welding of reinforcing plate to shell, the location of nozzle and manholes shall
be checked against the applicable drawings before cutting. Before commencement of
welding, the jigs shall be fixed on the opposite side of shell plates to prevent of welding
distortion. After Completion of welding, NDE of welds and inspection shall be completed.
5) Roof Structure
Rafter and Girder shall be marked and cut with actual dimension in the
drawing and Rafter clips shall be welded on the exact location indicated in
the drawing. If the rafter and girder is assembled with bolt/nut, the hole
shall be drilled by machine.
6) Roof Plate
The length and width of roof sketch plate shall be marked and cut carefully
in accordance with applicable drawings. In case of small diameter tanks,
the curvature of roof plate will be performed by roll bendor or pressing
machine.
5.7 Painting
Before delivery to site, all parts of the equipment shall be thoroughly cleaned of a
mill scale, rust, grease and other foreign materials and painted, if required, in
accordance with manufacturers practice and job requirement and all the document

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related to the painting will be submit. Painting work shall be accordance with the makers
Application Instructions and Painting Inspection Procedure.
1. Primer Painting
All external surfaces of plates, piping, etc shall receive a primer painting
according to the applicable Painting Schedule.
2. Coal Tar E p ox y
Coal tar epoxy paint only applied for the underside (direct touch to the
Bitumen of the foundation) of Annular Plate & Bottom Plate of the tank.
6. Dimensional Tolerance
6.1 Sh ell Plate
1. Prior to bending, Allowable tolerance of shell plate shall be as follows.

2. Curvature and distortion of shell plate shall be checked by means of a

template, and allowable tolerance shall be as follows.

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FABRICATION PROCEDURE
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3. The end of shell plate bended by roll bendor shall be inspected carefully
whether its curvature is avoided the over bending or the incomplete
bending.
4. The tolerance of bevel shall be in accordance with applicable drawing. If
the tolerances of bevel are not specified in the drawing, they shall be as
follows.

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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
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6.2 Bottom Annular Plate

Allowable tolerance of bottom annular plate is as follows.

6.3 Roof p late

Allowable tolerance of roof plate is as follows.

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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
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6.4 Sh ell stiffener & Top ang le
1. Curvature shall be checked by means of a gage plate for the shell stiffener
& top angle, or by placing a shell stiffener & top angle along the marked line
of tank radius on platform.
2. Curvature tolerance of shell stiffener is as follows:

6.5 Roof Structure

Allowable tolerance of roof structure is as follows.

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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
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6.6 Noz z le and Manh ole attach ed to sh ell p late

Allowable tolerance of Nozzle and Manhole attached to shell plate shall be as
follows.

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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
REV.
:!
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FABRICATION PROCEDURE
DOC NO. : SSNP-GEN-MEC-VDR-005
PROJ - 1051 - FAB - 001
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ATTACH ME NT 1. Tank Fabrication Process Ch art

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