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PT.

MULTI FABRINDO GEMILANG


PROCEDURE MANUAL
FABRICATION, ERECTION AND
INSPECTION

DOCUMENT NO.
MFG-DOC-100C
PAGE
i OF v

REVISION
0

CONTENTS
Page
SECTION I

SCOPE OF WORK

SECTION II

APPLICABLE CODES AND STANDARDS

SECTION III

MATERIAL RECEIPT AND STORAGE

SECTION IV

EQUIPMENT

SECTION V

FABRICATION

SECTION VI

FOUNDATION INSPECTION

SECTION VII

BOTTOM PLATE ASSEMBLY

Arrangement and assembling of bottom plates


Arrangement of annular plates
Setting of central bottom plate
Arrangement of peripheral bottom plates
Welding of bottom plates
Finishing of bottom plates

6
6
8

7.1
7.2
7.3
7.4
7.5
7.6
SECTION VIII

8
9
10

SHELL PLATE ASSEMBLY

11

8.1

Preparation

11

8.2

Jigs attachment

12

8.3

Shell plate attachment

12

8.4

First course shell plate assembly

8.5

Measurement of the first stage shell plate and clean out door connection

17

8.6

Assembly of 2-nd and the subsequent course shell plates

19

8.7

Assembly procedure of shell plates

20

8.8

Welding of shell plates

20

8.9

Assembly of top curb angles

22

SECTION IX

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ATTACHMENT ASSEMBLY

14

23

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PROCEDURE MANUAL
FABRICATION, ERECTION AND
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SECTION X

Column erection

10.2

Roof truss assembly

10.3

Welding
:

PAGE
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ROOF STRUCTURE ASSEMBLY

10.1

SECTION XI

DOCUMENT NO.
MFG-DOC-100C

24

24
25
25
26

ROOF PLATE ASSEMBLY

11.1

Arranging and assembling of roof plates

26

11.2

Roof plate welding

27

WATER FILLING AND DRAIN

27

SECTION XIII :

INSIDE TANK CLEANING

28

SECTION XIV :

WELDING MANUAL

28

SECTION XII

14.1

General

29

14.2

Welding detail

29

a) Surface preparation

29

b) Weld deposit

29

c) Slag removal

30

d) Maximum layer thickness

30

e) Welding teamwork

30

f) Welding equipment and tools

30

g) Welding electrodes

30

h) Welding supports, jigs, and lugs

30

i)

Tack Welding

31

j)

Limitation of performing welding

31

k) Additional welding practice for bottom plate


l)

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Additional welding practice for shell plate

31
32

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DOCUMENT NO.
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m) Additional welding practice for roof plate

32

n) Additional welding practice for shell attachment

32

14.3

Welding criteria

14.4

Repair of defective weldings

33

: INSPECTION MANUAL

34

15.1

General Items

34

15.2

Inspection of bottom and annular plates

35

15.3

Shell plate inspection

36

15.3.1 Horizontality, plumbness, and roundness

36

15.3.2 Edge preparation and face alignment

38

SECTION XV

15.3.3 Weld inspection


15.4

15.5

32

39

Roof plate inspection

39

15.4.1 Arrangement inspection

39

15.4.2 Weld inspection

39

15.4.3 Leakage Test

39

Other Inspections

40

15.5.1 Vacuum Testing

40

15.5.2 Auxiliary part inspection

40

15.6

Leakage Testing

40

15.7

Check for the unevenness of bottom plates

41

15.8

Check for mounting angles of shell and annular plates

41

15.9

Water filling test

41

15.10

Vacuum test of bottom and roof plates

41

15.11

Liquid penetrant test / Oil test

43

Tables
1. Permissible undercutting

33

2. Tolerance value for horizontality, plumbness, and roundness

36

3. Weld height tolerance

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DOCUMENT NO.
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Figures
1. Levelness check points on the existing foundation

2. Center positioning of bottom plate arrangement

3. Marking of backing strip position on bottom plates

4. Annular bottom plate arrangement

5. Jig attachment for bottom plate erection

6. Welding technique for annular plate welding

7. Setting central bottom plate

8. Arranging peripheral bottom plates

9. Welding sequence for bottom plates

10

10. Marking-off reference lines for shell plate assembly

11

11. Jig attachment for shell plate assembly

12

12. Markings for horse shoe and hook position

13

13. Horse shoe and hook attachment for shell erection

13

14. Jig attachment for shell plate erection

14

15. Shell plate assembly

15

16. Attachment for 1-st stage shell plate erection

16

17. Jig attachment detail for shell erection

16

18. Jig attachment detail for shell erection

17

19a. Levelness measurement

17

19b. Correction measurement of levelness

18

20. Perpendicularity measurement

18

21. Roundness measurement

19

22. Horse shoe attachment for upper courses

19

23. Assembly of upper courses

21

24. Welding sequence between shell plate joints

21

25. Top curb angle erection

23

26. Temporary reinforcement for tank opening welding

24

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27. Column erection

25

28. Rafter erection

26

29. Marking on roof plates for overlapping allowance

27

30. Bottom plate alignment

35

31. Horizontality measurement

37

32. Plumbness measurement

37

33. Face alignment

38

34. Groove angles

38

35. Vacuum test for flat surface joints

42

36. Liquid penetrant / Oil test

43

Appendix A Jig tools for Tank erection

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PROCEDURE MANUAL
FABRICATION, ERECTION AND
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I.

DOCUMENT NO.
MFG-DOC-100C
PAGE
1 OF 43

REVISION
0

SCOPE OF WORK
This manual covers the fabrication, erection, installation, sand blasting and painting, inspection and
testing of welded steel storage tank.

II.

APPLICABLE CODES AND STANDARDS


This manual shall be carried out in accordance with the followings,
1.
2.
3.
5.

API STD 650


Welded Steel Tank for Oil Storage
ASME Section V
Non Destructive Examination
ASME Section IX
Welding and Brazing
SSPC - SP 6
Commercial Blast Cleaning
- SP 10
Near White Blast Cleaning
- VIS 1
Pictorial Standard
6. Clients Specification, if any
7. Approved Construction drawings
III.

MATERIAL RECEIPT AND STORAGE


III.1 Unloading of material and parts such as plates, structures, welding electrode / filler metals,
painting material etc. from trailer truck to site storage will be carried out by crane.
III.2 Steel plates, steel structures, steel pipes and large diameter elbows will be at open yard storage
and will be supported adequately.
III.3 Welding Electrodes / Filler metals will be at warehouse in condition as recommended by filler
metal manufacturer.
III.4 Painting materials will be stored in the original container / box in protected areas with
condition recommended by paint manufacturer.
III.5 Other small components such as flanges, bolts, nuts etc, will be at warehouse.
III.6 For easy handling, all materials at storage will be in standard position.
III.7 Every delivery of materials shall be accompanied by a packing list enumerating material
description, specification and quantity. Its the responsible of the receiving party to fill in a
checking list to assure that the delivery turn to be the same as the packing list says, and that
there is no unacceptable damaged condition. If material arrives at its destination in damaged
condition, the receiving party shall promptly notify, or immediately upon discovery, the carrier
and consignee prior to unloading the materials.

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IV.

DOCUMENT NO.
MFG-DOC-100C
PAGE
2 OF 43

REVISION
0

EQUIPMENT
4.1

All chaines, hand tools and erection tools for fabricating and assembling work will be
checked and adjusted before start of work.

4.2

Electric equipment will be checked for leakage and insulation before start-up.

4.3

All equipment relating to the work will be removed and covered to original condition after
completion of work.

V.

FABRICATION
5.1

Prior to fabricating, materials to be used will be checked and complied with the approved
construction drawings.

5.2

Lay out of plates will be carried out in accordance with approved construction drawing.
Shrinkage by welding and distance between welding lines are carefully considered.

5.3

Cutting of material and edge preparation will be carried out by means of gas and / or plasma
cutting equipment, beveller and other mechanical equipment. When edge surfaces are
uneven and shapes of them not uniform, the surfaces will be ground smoothly by means of a
grinder.

5.4

Welding groove dimension will be checked by means of welding gauge. Tolerance for groove
angle as per approval construction drawing and/or related Welding Procedure Specification.

5.5

Rolling of plates will be carried out by means of Hydraulic Rolling Machine and special
attention to be considered for curvature of edge of rolled plates. After press work, the rolled
plates will be placed at open yard storage and supported by wooden to prevent straightening
of curvature.

5.6

Bending of steel structures such as top curb angle, compression ring, railing pipes, etc. will
be carried out by means of partial bending machine.

5.7

The press work will be carried out so as not to sharpen any shapes or to make smooth
changing of any shapes.

5.8

All welding works will be carried out in accordance with paragraph XIV of this manual.

5.9

Upon completion of fabrication and before final acceptance, falsework, rubbish, any scraps
and temporary buildings, if any, will be thoroughly removed.

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VI.

DOCUMENT NO.
MFG-DOC-100C
PAGE
3 OF 43

REVISION
0

FOUNDATION INSPECTION
VI.1

For the purpose of ascertaining the integrated quality of the tank to be constructed,
especially for erection work, the foundation again will be inspected in the presence of client
and /or constructor of the foundation, and the erector. The inspection results shall conform to
the previous inspection report and drawings of the foundation. Any unacceptable
discrepancies shall be notified promptly to the client and/or the foundation constructor prior
to erection work.

VI.2

The following items should be taken into account while conducting the inspection.
(1)

Position and height of center and bench mark reference points.

(2)

Completion of basic inking at 0, 90, 180, and 270 on concrete of tank periphery

(3)

Shape, dimension and level of concrete

(4)

Execution and tapering of dried sand

(5)

Receipt of inspection report for foundation from constructor of foundation.

(6)

Make-up of the minutes pertaining to completion of foundation

(7)

Outlook of finish dimension and level

(8)

Clean-out-door position

(9)

Circumstance at completion of foundation, storage of materials, secureness of space,


etc.

VI.3

For level check at completion of foundation, the points marked should be checked in the
figure on the next page, and middle points between marked points may be arbitrarily
checked.

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DOCUMENT NO.
MFG-DOC-100C
PAGE
4 OF 43

Fig. 1 Levelness check points on the existing foundation


NOTES :
A is Center point of tank
B is One-third radius of tank
C is Two-third radius of tank
D is Point at bottom plate periphery
E is Outside diameter of concrete

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6.4

DOCUMENT NO.
MFG-DOC-100C
PAGE
5 OF 43

REVISION
0

Orientation on the foundation


(1)

Establishing of azimuth
After confirming the completion of foundation work, mark with paint on the
concrete surface the azimuth lines of 0, 90, 180 and 270. These lines and their
intersection, centre of the foundation, should be the datum of the assembly.

(2)

Centre positioning for bottom plate arrangement.


(a)

Mark-off the annular plate outside circle on the concrete from the foundation
center. This circle should be 10 mm large in diameter than that of drawing
dimension.

Typical example

Fig. 2 Center positioning of bottom plate arrangement


(b)

Mark-off reference points


Provide a reference point mark V for arranging the bottom on the annular
plate outside circle according to the bottom plate drawing.

(c)

Draw reference lines.


Connect the opposite reference points with a line. The intersection of two lines
must be coincident with that of azimuth lines.

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PROCEDURE MANUAL
FABRICATION, ERECTION AND
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VII.

BOTTOM PLATE ASSEMBLY

7.1

Arrangement and assembling of bottom plates.

DOCUMENT NO.
MFG-DOC-100C
PAGE
6 OF 43

REVISION
0

(a)

Marking-off of the matching line ( center line ).


Mark off the center line on the annular plate.

(b)

Mark-off the reference line, weld the backing strip on the central and peripheral bottom plates
as shown below.

Fig. 3 Marking of backing strip position on bottom plates


7.2

Arrangement annular plates


(a)

Lay the annular plate matching with the line marked-off according to the paragraph 6.5. This
plate should be the datum for the annular plate arrangement. Lay the annular plate one by one
along the circle provided beforehand, then fit the final annular plate.

(b)

After arranging the annular plate, coordinate the adjoining annular plates, check the root
opening and arrange offset of them, and then execute tack welding. After the tack welding, fix
the plates with restraining jigs and execute regular welding, except for annular plates where
clean-out-doors to be installed.

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Fig. 4 Annular bottom plate arrangement

(c)

After completing the regular welding, finish approximately 100 mm welds, which will contact
with the shell plate bottom, flush with the surface of annular plate using a grinder.

Fig. 5 Jig attachment for bottom plate erection

Fig. 6 Welding technique for annular plate welding

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7.3

DOCUMENT NO.
MFG-DOC-100C
PAGE
8 OF 43

REVISION
0

Setting of central bottom plate


When laying and adjusting bottom plates, care should be taken so as not to damage the foundation.
At first, the central bottom plate should be set as shown below. Take care in setting so as to conform
to the figure below.
Typical example

Fig. 7 Setting central bottom plates

7.4

Arrangement of peripheral bottom plates


(a)

After setting the central bottom plate, lay the peripheral bottom plates from center to
periphery.

(b)

Execute tack welding on the bottom plate before the regular welding.

(c)

The overlapping allowance between bottom plates and annular plate must conform to that of
drawing dimension.

(d)

Remove foreign matters such as sand and dust on the area to be overlapped.

(e)

When executing regular welding of bottom plates, be careful with the welding procedure and
usage of jigs in order to minimize distortion and absorb the contraction due to welding by
applying welding as designated by welding procedures on tack and regular weldings.

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REVISION
0

Typical example

Fig. 8 Arranging peripheral bottom plates

7.5

Welding of bottom plate


(a)

Butt welding with backing strips will be utilized for bottom plate welding.

(b)

In full consideration of weld strain, welding will be performed by changing sequence of bead
welding such as symmetric welding sequence, back step process, ship welding etc. Welding
will be performed from the center towards the outside to draw or allow strain to go to the
outside, as shown on drawing below.

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0

Fig. 9 Welding sequence for bottom plates

7.6

(d)

Welding will be carried out in the direction of short joint first and then followed by tack
welding of long joint, then the next regular welding will be carried out in the direction of
longitudinal joint.

(e)

All welding works will be carried out in accordance with paragraph XIV of this manual.

Finishing of bottom plates


(a)

After welding the bottom plate, remove the attached jigs carefully so as not to give damage to
the base metal, and finish the welds with a grinder.

(b)

Where the peel-off or cut-away of base metal is produced while removing the jigs, execute
repair welding on the damaged area and finish with a grinder.

(c)

The depth of undercut must conform to the inspection manual.

(d)

For bottom plate inspection see paragraph 15.2

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PROCEDURE MANUAL
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VIII.

SHELL PLATE ASSEMBLY

8.1

Preparation

DOCUMENT NO.
MFG-DOC-100C
PAGE
11 OF 43

REVISION
0

After completing bottom plate inspection, execute the following items of work as the preparation for the
assembly.
(a)

Mark-off the orientation 0, 90, 180, and 270 lines for the reference of shell plate erection
corresponding to the foundation datum line.

(b)

Mark-off the inside diameter circle of shell plates.

(c)

Mark-off the circle for the datum of checking the assembly of shell plate, that is 100 mm
inward from the inside diameter circle of shell plates.

(d)

Mark-off the point for datum of assembling the shell plates.

Typical Example

Fig. 10 Marking-off reference lines for shell

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8.2

DOCUMENT NO.
MFG-DOC-100C
PAGE
12 OF 43

REVISION
0

Jigs Attachment

After marking-off the shell plate inside diameter, attach jigs for fitting shell plates as shown below.

Fig. 11 Jigs for bottom-to-shell plate assembly

8.3

Shell plate attachment

Before erecting shell plates, attach jigs for assembly and hooks for foot boat bracket.
NOTE : The position, size, and number of jigs should be determined at site.

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Fig. 12 Markings for horse-shoe and hook position

Fig. 13 Horse shoe and hook attachment for shell erection

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Fig. 14 Jig attachment for shell plate erection

8.4

First course shell plate assembly


Assembling of the first stage shell plate starting from the assembling datum point, arrange the first
stage shell plates clockwise, or counterclockwise, and assemble them based on the marking-off
provided beforehand, then execute tack welding.

Note : The space between jigs should be determined regarding warp due to welding.
(a)

Lift the shell plate and bring onto the bottom plates, match the end of the shell plate with the
reference line, and fix the plate with jigs and prevent fall-down of the plate, and maintain
perpendicularity.

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DOCUMENT NO.
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REVISION
0

(b)

Arrange and adjust clean-out-doors and execute the same handling as in the above item a),
then apply the specified spacer between the abutting clean-out-door reinforcement plate, and
fix with fitting jigs.

(c)

Arrange the second and subsequent shell plates one by one clockwise, or counterclockwise,
and execute the same handling as in the above item a), then apply specified spacers between
the abutting plates, and fix with fitting jigs.

(d)

After arranging shell plates, check them for arrangement by adjusting with bottom piece,
wedge etc, along the shell plate inside diameter circle, at the same time, coordinate the groove
of longitudinal joint and round edge.

Fig. 15 Shell plate assembly

Note : The space between jigs and between spacers should be determined regarding the plate size,
warp due to welding, etc.

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(e)

DOCUMENT NO.
MFG-DOC-100C
PAGE
16 OF 43

REVISION
0

After assembling the first stage shell plates and clean out-door, check them for
perpendicularity, levelness, roundness, etc in accordance with the inspection manual and the
error, if any, must be within the tolerance.

Notes :
1. Root opening should be adjusted with spacer.
2. Plate to-plate fitting should be adjusted with strong back, spacer, etc.

Fig. 17 Jig attachment detail for shell erection

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0

Fig. 18 Jig attachment detail for shell erection

8.5

Measurement of the first stage shell plate and Clean-out-door connection.

As the figure below shows, measure the shell plate for levelness, perpendicularity, and roundness in
circumferential direction. Correct the error, if any, and must be within the range tolerance stipulated in the
inspection criteria.
(a)

Measurement of levelness and correction

Fig. 19a Levelness measurement

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Fig. 19b Correction measurement of levelness

Note : 1.
2.
(b)

Correction should be made between bottom plate and foundation with liner and wedge.
Must conform to the inspection manual for tolerance.
Measuring perpendicularity and correction
The measurement should be made based on the shell plate assembling checking circle markedoff beforehand.

Fig. 20 perpendicularity measurement

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Fig. 21 Roundness measurement

(c)
8.6

Measuring of roundness and correction


The shell plate assembly checking circle should be the datum for measurement.

Assembling of second and subsequent course shell plates.

Attaching of jigs for shell plate assembling with horse shoe and inside surface of shell plate in the same
manner as in the 1-st stage shell plate.

Fig. 22 Horse-shoe attachment for upper courses

(a)

Extend and assemble the second and subsequent shell plates with straight strong back, curved
strong back, bull pin, etc. being careful with the root opening and offset of circumferential and
longitudinal jonts.

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8.8

PAGE
20 OF 43

REVISION
0

(b)

Execute the assembly stage by stage until the uppermost stage is achieved.

(c)

When proceeding to the next stages, execute checking for levelness perpendicularity, and
roundness in accordance with the inspection manual, the error, if any, must be within the
tolerance.

Note :
8.7

DOCUMENT NO.
MFG-DOC-100C

The space between spacers should be determined regarding the plate size warp due to
welding, etc.
Assembly procedure of shell plates.
1)

Assembling of 1st stage shell plates and Clean-out door.

2)

Tack welding of 1st stage shell plates and Clean-out-door

3)

Assembling of 2nd stage shell plates.

4)

Tack welding of 2nd stage shell plates

5)

Vertical welding of 1st stage shell plates and Clean-out door.

6)

Vertical welding of 2nd stage shell plates

7)

Horizontal welding of 1st and 2nd stage shell plates

8)

Assembling of 3rd stage shell plates

9)

Tack welding of 3rd stage shell plates

10)

Vertical welding of 3rd stage shell plates

11)

Horizontal welding of 2nd and 3rd stage shell plates

12)

And so on until all stages of shell plates completed

Welding of shell plates


(a)

Shell plate welds will be performed from the bottom course shell plates.
Vertical joint on shell plates is carried out first and after completion of weld on adjacent shell
plates, upper and lower stages, fitting of circumference of shell plates, tack welding and
regular welding will then be carried out.

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Fig. 23 Assembly by upper courses

Fig. 24 Welding sequence between shell plate joints

(b)

Vertical and circular joint of weld on shell plates will have complete penetration with no
undercutting.

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8.9

DOCUMENT NO.
MFG-DOC-100C
PAGE
22 OF 43

REVISION
0

(c)

After the outside of shell is welded, the inside will be welded. In order to make a complete
penetration, at each distance of 80 mm to both sides from vertical joint with circular joint
intersects, vertical joint will be back chipped by using a grinder or arc gouging. Weld flaw on
the first layer of outside weld will be completely removed. After back chipping and extreme
uneven area, slag and flaw will be finished by using a grinder.

(d)

Proper width and depth will be made so as to make inside welding easy.

(e)

Weld on the upper and lower edges of vertical joint will be carefully performed in such a way
so as not to make weld flaw in particular. When circular and vertical joint weld is carried out it
will be visually confirmed again.

(f)

After finishing of vertical weld joint on the first stage of shell plates, fillet weld on bottom and
shell plates will be carried out. Make 8 to 10 place along circumference for draining water
during tank construction by leaving these places unwelded. These places shall be marked
clearly and shall be welded just before filling the tank with water.

(g)

The attachment of shell plates and bottom plates will be T-joint of both side continuous fillet
weld with 6 mm throat thickness.

(h)

Circular joint will be fitted one after another and welded upon completion of vertical joint weld
on upper and lower stage of adjacent plate.

(i)

All welding works will be carried out in accordance with paragraph XIV of this manual.

Assembly of top curb angles.


(a)

Lay a channel on the uppermost shell course together with a pair of horizontal strong backs.

(b)

Install top curb angle piece by inserting it between strong backs on one end and lay the other
end on the channel.

(c)

Check roundness prior to performing tack welding

(d)

Attach temporary supports, approximately one feet apart, welded on face end of top curb
angle and on shell plate from strong backs to channel, then shift the channel as necessary while
attaching these supports.

(e)

Recheck radius

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(f)

Start welding along top curb angle length and leave about 2 meter long to compensate for
welding distortion.

(g)

Repeat step a) to f) for the next top curb angle piece adjacent to it.

(h)

Perform welding of vertical joint between the first and the second pieces of top curb angle.

(i)

Complete the remaining horizontal welding of the first piece of top curb angle.

(j)

And so forth until reach the circumference of the tank.

Fig. 25 Top curb angle erection

IX.

ATTACHMENT ASSEMBLY

9.1

Open a manhole in the attendance of companys personnel in charge after adjusting the horizontality,
perpendicularity, and roundness of 1st stage shell plates, and then install the patch nozzle after the
3rd stage shell plates have been welded.

9.2

Other auxiliaries to be attached to shell plate and roof plate, after completion of shell plate and roof
plate welding respectively, mark-off its orientation, elevation, size, etc. to conform to the
specification such as orientation, elevation, and size on the construction drawing, and checked by the
witness of companys person in charge to open the manhole.

9.3

Strengthen shell plate with reinforcements to prevent the shell plates from straining due to welding of
manholes, nozzles, etc.

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All weldings will be carried out in accordance with paragraph XIV of this manual.

Fig. 26 Temporary reinforcement for tank opening welding

X.

ROOF STRUCTURE ASSEMBLY

10.1

Column erection
Take in and erect columns by using a crane after assembly of third to fourth stage shell plates. In this
case, for the prevention of falling of the columns, strain wire ropes and adjust perpendicularity with
lever blocks.

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Fig. 27 Column erection

10.2

10.3

Roof truss assembly


(a)

After erection of center and intermediate columns, if any, install girders between columns.

(b)

After the assembly of all the plates, weld traps on the plates, and install rafters from the
centre.

Welding
All weldings will be carried out in accordance with paragraph XIV of this manual.

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Fig. 28 Rafter erection

Note : Take over columns, girders, and rafters by using a rolling tower.
XI.

ROOF PLATES ASSEMBLY

11.1

Arranging and assembling of roof plates


(a)

Put roof plates in order after the assembly of the roof truss, check the inside and outside of
each roof plate on ground before lifting.

(b)

Mark-off the reference line, the overlapping allowance, etc, on the central and peripherical
roof plates as shown below.

(c)

Put roof plates in order commencing from the outer circumference to the centre, in case of
double lap joint and vise verse for single lap joint, in accordance with the assembly drawings.

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Fig. 29 Markings on roof plates for overlapping allowance

11.2

XII.

(d)

Overlapping allowance of roof plate should be 40 mm and above.

(e)

Way of putting roof plates in order apply correspondingly to manual of arrangement procedure
of lap welded bottom plates.

Roof plate welding


(a)

Roof plates will be in proper sequence so as to minimize straining.

(b)

Weld will be carried out toward the outside from the center in principle

(c)

Weld on truss will not be carried out

(d)

Outside fillet weld will be carried out for roof plates and top angle. Size of weld zone will be
less than 4.8 mm.

(e)

All weldings will be carried out in accordance with paragraph XIV of this manual.

(f)

Prior to welding, make sure that all rafters are in close contact with the associated roof plate
inside.

WATER FILLING AND DRAIN

After the assembly and welding of all shell plates, fill water into the tank. Prior to water-filling, the following
items should be checked.

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XIII.

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(a)

Check each welded section and repaired section.

(b)

Remove all unnecessary jigs both in the inside and outside tank and each installed section.

(c)

Check to see that all permanent attachments have been installed correctly and that related
prime valves and blind plates are installed correctly.

(d)

Water-filling speed and retaining period should be indicated by client /customer.

(e)

When filling tank with water, keep watching the tank for any possible leakage of water and
stop filling promptly after leakage is discovered. During water filling, draw up inspection
records of water level at each section.

(f)

While filling water, the foundation submersion should be measured by foundation constructor
in the event of high submersion speed or uneven submersion. Should this event happens, stop
water filling temporarily and immediately consult to client/ customers personnel in charge
prior to proceeding to the remaining water filling.

(g)

Water should be filled up to 50 mm high above the tank top

(h)

While filling water and draining, open roof manhole with much care without giving excessive
pressure on the inside of the tank or destroying because of vacuumity.

(i)

Drain the filled water gradually to the designated place.

INSIDE TANK CLEANING

Clean tank inside by using fresh water after draining the water. After cleaning remove all muddy water left on
the bottom in rags. Each item should be inspected in accordance with the inspector manual attached
separately.
XIV.

WELDING MANUAL

Terms relating to welding shall be interpreted as defined in Section IX of the ASME Code.

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14.1

14.2

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General
(a)

Welding will be carried out by manual SMAW with covered electrode and shall be in
accordance with the qualified Welding Procedure Specification ( WPS ) and performed by
qualified welder.

(b)

Welder and Welding Procedure Specification will be qualified in accordance with the Section
IX of ASME Boiler and Pressure Vessel Code referring to the latest edition and addendum.

(c)

The welder identifying mark or code, could be a number, letter, symbol or any combination,
shall be marked, either by hard stamp or by paint marker, adjacent to the welded joint and at
intervals of not more than 3 feet along the welds made by the each welder. These marks shall
be available to the inspector. The marks shall also include the date and results of tests.

Welding detail

Tanks and their structural attachment shall be welded by manually or semi automatically according to
procedures described in Section IX of the ASME Code.
(a)

(b)

Surface Preparation
1.

The edges or surfaces of parts to be joined by welding will be made uniform, smooth
and cleaned of all foreign materials such as moisture, slag, oil, grease, paint, scale or
rust by grinding or brushing. Cleaning will be done by in such a way that will not lead
to contamination to the weld.

2.

Various foreign substance such as moisture, oil, dust, oxidized film or slag on melted
metal or back chipped area will be completely removed before starting the next
welding stage.

3.

The work and all surfaces to be welded will be protected from wind, rain and other
harmful weather condition.

4.

Offset of butted edges will be within the tolerance stipulated in inspection manual.

Welding joint will be made by completing each weld layer before the succeeding weld layers
are deposited and block welding will not be applied unless otherwise accepted for specific
application.

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(c)

Each layer of weld metal shall be cleaned of slag and other foreign material by a grinder
before proceeding to the next layer, in case of multi layer welding.

(d)

The maximum individual layer thickness will be kept not exceed 9 mm.

(e)

Welding teamwork
Welding will be performed by a welding team work consisting of at least one welder, one
fitter, one helper, and under supervision of welding supervisor.

(f)

Welding Equipment and tools


Welding machine, welding rectifier, generator, welding gloves, welding cap, a grinder, wire
brush and any other welding aids will be ready for use before, during, and after welding.

(g)

(h)

Welding Electrode
1.

For base metal having a minimum tensile strength less than 80.000 psi, manual arcwelding electrodes shall conform to the E60 and E70 Classification Series.

2.

Electrodes of low hydrogen content shall be used for manual SMAW, including the
attachment of the first shell course to the bottom or to annular bottom plates.

3.

Drying of low hydrogen electrodes will be carried out in accordance with


manufacturer recommendation by means of an electrode oven.

4.

Electrodes of carbon steel covered type, diameter and chemical composition assigned
by F Number as specified by qualified WPS will be utilized to all weldings.

5.

Electrodes or filler metal will be kept in their original boxes and stored in a warehouse
at room temperature not less than 20 Celcius.

Welding Supports, Jigs, and Lugs


1.

Prior to start welding, alignment shall be rechecked and provide proper support and/or
jig to compensate for shrinkage and to maintain the sound shape of base metal.

2.

Lugs attached by welding shall be removed, and any noticeable projections of weld
metal shall be chipped from the plate. The plate shall not be gouged or torn in the
process of removing these lugs.
PT. MULTI FABRINDO GEMILANG
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(i)

Tack Welding

(j)

1.

Check alignment, bevel, and gap prior to tacking.

2.

Tack weld material shall be the same as that of filler metal.

3.

Tack weld of grooves will be removed by means of grinder.

When vertical joints of tank shell are welded manually by SMAW process, tack welds
used in the assembly of the joints shall be removed and shall not remain in the finished
joint. But if Submerged Arc Welding ( SAW ) process is applied tack welds may be
left in place provided that they are thoroughly cleaned of all welding slag, sound and
thoroughly fused into subsequently applied weld beads.

5.

Tack welds to be left in place shall be performed by qualified welders and shall be
visually examined for defects which shall be removed if discovered.

6.

Tack welds shall be made using a fillet weld or butt weld procedure qualified in
accordance with section IX of the ASME Code.

Limitation of performing welding


Under any circumstances, no welding shall be performed when
1.
2.
3.
4.

(k)

The surface(s) of the parts to be welded is wet.


During periods of high wind unless the welder and the work are properly shielded.
The temperature of base metal is less than 0 F.
In case of base metal temperature is between 0 F to 32 F or the thickness is greater
than 1 inches, the base metal shall be preheated within 3 inches of the place in
which welding will be applied to a temperature warm to the hand before starting to
perform welding.

Additional practice for BOTTOM PLATE welding


1.

To provide as nearly as possible a plain surface, bottom plates shall be joined by


welding in a sequence as stipulated on paragraph 7.5 of this manual.

2.

To compensate for shrinkage of any welds previously made, welding of bottom joints
may be left open. The remaining welding will be completed after completion of shell to
bottom or annular bottom welding.
PT. MULTI FABRINDO GEMILANG
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(l)

Additional practice for SHELL PLATE welding

(m)

1.

To maintain shell curve, shell plates shall be joined by welding in a sequence as


specified on paragraph 8.7, matched accurately and retained in position during
welding operation.

2.

Permanent and temporary attachments shall be welded by a procedure that does not
cause under bead cracking.

3.

The necessity of preheat for thick plates or for a low atmospheric temperature during
welding shall be taken into account when selecting the procedure.

Additional practice for ROOF PLATE welding


At all lap joints, plate shall be held in close contact during welding operation.

(n)

14.3

Additional practice for shell attachment


1.

Shell attachments are defined as surface attachments, such as fit-up equipment, angle,
clips, and stair treads.

2.

Permanent and temporary attachments to shells shall be welded with low-hydrogen


electrodes.

3.

Permanent attachments may be welded directly to the shell with fillet welds having a
maximum leg dimension of inch. The edge of any permanent attachment welds shall
not be closer than 3 inches from horizontal joints of shell nor closer than 6 inches
from vertical joints of shell or reinforcing plate fillet welds.

4.

Temporary attachment to shell courses shall preferably be made prior to welding of


the shell joints and shall be removed, and any resulting damage shall be repaired and
ground to a smooth profile.

Welding criteria

A weld shall be acceptable by the following visual inspection.


(a)

No excessive surface porosity


In any four inches of weld length the surface porosity doesnt exceed one cluster, one or more
pores, and the diameter of the cluster does not exceed 3/32 inch.
PT. MULTI FABRINDO GEMILANG
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(b)

No crater cracks or other surface cracks.

(c)

No excessive undercutting as the following table

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Table-1. Permissible Undercutting


Kind of joint

Max. acceptable
Undercutting
1/64 inch in depth
1/32 inch in depth
1/64 inch in depth

Vert. Butt joint ..


Horiz. Butt joint ...
Lap joint sections of bottom plates ..
Any joint in nozzles, manholes clean out openings and
permanent attachments..
1/64 inch in depth

After proving that a joint is acceptable by visual inspection, other inspections such as Radiographic,
Magnetic Particle Inspection, Liquid Penetrant Inspection or Water Filling Testing may be conducted.
Acceptance standard, removal, and repair of defects for Radiographic shall be judged by the standards in
Section VIII, Division 1, Paragraph UW 52 of the ASME code.
Acceptance standard, removal, and repair of defects for Liquid Penetrant Inspection shall be judged by
standards in Section VIII, Division 1, Appendix 8, Paragraph 8-3 and 8-4 of the ASME Code.
Acceptance standard, removal, and repair of defects for MPI inspection shall be per Section VIII, Division
1, Appendix 6, Paragraph 6-3 and 6-4 of the ASME Code.
14.4

Repair of defective welding


Any weld that fail to meet the criteria given in paragraph 14.3 shall be reworked prior to hydrostatic
testing with the following manners.
The defects shall be removed by grinding or thermal gouging process.
Back chipping will be carried out by means of a grinder and/ or arc air gouging.
Defects in welds shall be repaired by chipping or melting out the defects from one side or both sides
of the joints, as required, and then re-welding will be performed.
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All repaired welds shall be rechecked by repeating the original inspection procedures and testing to
assure that there is no another new defect discovered.
If removal cause the plate thickness to be less than the calculated minimum required thickness based
on hydrostatic test condition, re-welding shall be performed.
Master-proc/Tank/Fabr-c.wrd

Weld flaw discovered by visual inspection will be repaired. In case of built-up welding, repair will be
performed under the instruction of our welding supervisor and welding inspector. The followings are
kinds of weld flaw with their respective repair.

XV

(a)

Crater, pit
Repair by hammering such flaw and other unsightly flaws which are deeper than the
specified value on the welded surface will be ground flat and smooth by using a
grinder.

(b)

Uneven shape of beads


Such flaw will be removed by grinding

(c)

Undercutting
Joint that doesnt meet paragraph 14.3c will be re-welded without removal of previous
bead.

(d)

Crack
Such flaw will be removed, and then re-welded and repaired after confirmation that
there is no more crack with the aid of Magnetic Partical Inspection. For deposited
weld crack extending to base metal, quality of base metal will be checked carefully. If
there is no problem in the quality of base metal, crack will be removed after
confirmation by Magnetic Particle Inspection and Client approval. In case of crack
extending to tank attachment, the attachment will be changed and then re-welded.

(e)

Open lamination
Any open lamination on the edge surface of the plate will be removed after
confirmation by Magnetic Particle Inspection that there is no flaw, the flaw area will
be re-welded.

INSPECTION MANUAL
15.1

General items
1)

The inspection of this construction should be executed in accordance with this manual
standards, drawings, related laws and regulation, and specification.
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2)
15.2

DOCUMENT NO.
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Whenever doubts are arisen during the inspection, such doubts will be discussed with
personnels in charge.

Inspection of bottom and annular plates

15.2.1 Visual inspection of plate arrangement


(a)

REVISION
0

The arrangement of plate direction should be checked with the drawing.

Master-proc/Tank/Fabr-c.wrd

(b)

The root opening dimension of plates, groove angle of plates will be checked by means of
Welding Gage.
The following should be inspected in the assembly of annular plates.

Fig. 30 Bottom plate alignment

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15.2.2 Weld inspection

15.3

(a)

All lines of the weld section should be visually inspected.

(b)

Check of numbers of weld layers and welders of each weld lines that should be made.

(c)

The allowable value for the undercut depth should be within values given in table-1.
The undercut of 0.4 mm or less shall be vanished by grinding it smoothly, and that of more
than 0.4 mm shall be repaired by welding to grind-finished.

Shell plates inspection

Master-proc/Tank/Fabr-c.wrd

15.3.1 Inspection of temporary assembly after the temporary assembly of the 1 st stage and the uppermost
stage of shell plates. The horizontality, the perpendicularity and roundness shall be measured. The
measuring points should be equally spaced along the circumference.
Table-2

Tolerance value for horizontality, plumbness, and roundness

Inspection
Horizontality
Plumbness
Roundness

(a)

Section

Allowable value

1st stage
uppermost stage
All stages

3 mm
10 mm
Tank Height / 200mm

1st stage
uppermost stage

15 mm
30 mm

Measurement procedure for horizontality


Before arranging shell plates in place, measure the level of bottom plates, at which the shell
plates to be installed. After mounting the shell plates on the bottom plates, place a level in the
centre of bottom plates and measure the distance from the top of shell plates.

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Fig. 31 Horizontality measurement

(b)

Measurement procedure for roundness including perpendicularity.


After marking a certain radius on the bottom plate, suspend a plumb bob from the top
of the shell plate and the difference from the marking should be converted into
dimension.

Master-proc/Tank/Fabr-c.wrd

Fig. 32 Plumbness measurement

15.3.2 Inspection of edge preparation and face alignment


(a)

Face difference at the joint section of longitudinal and horizontal joint of the shell
plates should be as follows.
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aa : Longitudinal joints
Where the uppermost course shell plate thickness is 10 mm or less, the face difference
should be 1 mm. If the thickness more than 10 mm, the difference should be 10% plate
thickness or 1.5 mm, whichever the greater.
bb : Circumferential joints

Master-proc/Tank/Fabr-c.wrd

Fig. 33 Face alignment

Where the uppermost course shell plate thickness is less than 8 mm, the face
difference should be 1.5 mm. If the thickness is 8 mm or more the difference should be
20% top plate thickness or 1.5 mm, whichever the smaller. Measuring of face
differences should be carried out at the contact surface with thickness gauge.
(b)

Check for the steel plate numbers after arranging the shell plates in place.

(c)

The groove should be visually checked

(d)

Check for the groove angles and the root gap tolerance should be within the value
shown in the following figure.

Fig. 34 Groove Angles

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15.3.3 Weld inspection


(a)

Back chipping check


As the longitudinal and circumferential joints, the back chipping should be executed
until detrimental defects in the first layer are removed after welding the single side,
and check for the absence of such defects. The groove shape should also be visually
checked.

(b)

Visual inspection
Execute visual check for the welds and section with jigs and check to see that defects
such as undercut, overlap, etc are not found.
The height of weld exceeding the following allowable values after grinding for the
repair of undercut or excessive height, repair by welding and finish grinding.

Table-3 Weld height tolerance


Section

Master-proc/Tank/Fabr-c.wrd

Height of weld

Height of longitudinal joints

2.4 mm or less

Weld horizontal joints

3.0 mm or less

Reinforcements :
Place to which the radiographic examination is
applied

1.5 mm or less

15.4

Roof plate inspection

15.4.1 Arrangement inspection


When arranging roof columns, rafters and roof plates in place, the direction of the plate arrangement should
be checked with the drawings.
15.4.2 Weld inspection
All weld sections should be visually checked
15.4.3 Leakage test
When water filling, maintain a water level 50 mm above the top angle and check for the leakage at the weld
section of the roof by compressing and sending 50 mm Aq air into the tank with application of forming liquid
on the weld lines.
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15.5

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0

Other inspections

15.5.1 Vacuum test


Conduct vacuum test for bottom and annular plates before assembling the shell plates, execute 400
mm Hg vacuum test after welding up to approximately 300 mm in length of the exterior side of the
annular plate joint. Section to which the vacuum test applied should be as follows.
(a)

T-joints of shell and annular plates ( interior )

(b)

Welded joints of each annular plate

(c)

All welded joints of each bottom plate.


Execution period should be before water filling.

15.5.2 Auxiliary part inspection


(a)

Mounting inspection
Ensure that the mounting position and pieces are as specified with the orientation drawing and
the following inspection should be carried out.

Master-proc/Tank/Fabr-c.wrd

a.1 Nozzles on a shell plate should be checked for their height from the bottom plate and
nozzle centers, the length between the shell plates and flange faces, the groove angles,
and the mounting angles.
a.2 The edge of reinforcing plates employed at the shell plate opening of the nozzle should be
visually checked.
(b)

15.6

Weld inspection
All welded section should be visually checked.
The tolerance of undercut should be 0.4 mm or less.

Leakage test

For the purpose of detecting leakage through the interior welds, nozzles and manholes supported with
reinforcing plates, the welds should be checked by blowing in 1.5-2.0 Kg/cm G air from a - inch
diameter telltale hole with the application of forming liquid on the interior and exterior welded section. This
process is only for nozzles and manholes on shell plates.

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15.7

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Check for the unevennes of bottom plates

Equally space the tank bottom circumference into 8 or more, and the change for the radius
direction should be measured with level meters or by leaving string twice before water filling test
and after drainage.
15.8

Check mounting angles of shell and annular plates.

Equally space the tank circumference 8 or more, and then check for the presence of a change by measuring
the mounting angle before and after the water filling.
15.9

Water filling test

15.9.1 Method
(a)

Water filling should be executed with a temporary piping system.

(b)

Time taken for the water filling and retention time shall be discussed in advance.

(c)

The height of water filling should be adjacent to the top angle + 50 mm.

15.9.2 Inspection items during the test


(a)

Presence of leakage from the shell and the bottom plates.

Master-proc/Tank/Fabr-c.wrd

15.10

(b)

Presence of deformity of projection of the shell and the bottom plates.

(c)

Presence of leakage at the tank prime valves.

(d)

Presence of leakage from each flange gasket.

(e)

Check for level of the lowest course shell plates.

Vacuum test of bottom plates and roof plates.

Make a vacuum test in the flat type weld lines of bottom plates and the entire weld lines of root plates. No
leak should be found at pressure of 400 mm Hg.
Test Procedure
(1)

Remove thoroughly foreign matters such as slag, sand dust, and substance such as oil and
paint adhered on the weld line of bottom plates, then clean up the entire weld line with a wire
brush.
PT. MULTI FABRINDO GEMILANG
PROCEDURE MANUAL

FABRICATION, ERECTION AND


INSPECTION

DOCUMENT NO.
MFG-DOC-100C
PAGE
42 OF 43

REVISION
0

(2)

Apply soap and water solution, or forming agent, on the weld surface to be tested,
approximately 30 inches of the seam.

(3)

Set a vacuum tester over the coated section of the seam.

(4)

Run the vacuum tester by lowering pressure down to 400 mm Hg or little below, take care not
to lower to much, then close the valve and start testing after the pressure becomes stable.

(5)

Through a glass window in the top of this metal testing box, check visually to see whether or
not any bubble or foam is found on the surface applied soap and water solution. No pressure
increase or no foam indicate that the welding is acceptable.

Master-proc/Tank/Fabr-c.wrd

Fig. 35 Vacuum test for flat surface joints

PT. MULTI FABRINDO GEMILANG


PROCEDURE MANUAL
FABRICATION, ERECTION AND
INSPECTION

15.11

DOCUMENT NO.
MFG-DOC-100C
PAGE
43 OF 43

REVISION
0

Liquid penetrant / Oil test


Instead of vacuum test, oil test would be applied on round edge welds of inner fillet weld between 1 st
course shell plate and bottom plates or annular bottom plates, if any. This test could only be applied
on the inner fillet weld before performing welding of the other side.
No oil leak will indicate that the weld is acceptable.

Master-proc/Tank/Fabr-c.wrd

Fig. 36 Oil test

ATTACHMENT A

JIG TOOLS FOR TANK ERECTION

Master-proc/Tank/Fabr-c.wrd

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