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DOCUMENT NO.
MFG-DOC-100C
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CONTENTS
Page
SECTION I
SCOPE OF WORK
SECTION II
SECTION III
SECTION IV
EQUIPMENT
SECTION V
FABRICATION
SECTION VI
FOUNDATION INSPECTION
SECTION VII
6
6
8
7.1
7.2
7.3
7.4
7.5
7.6
SECTION VIII
8
9
10
11
8.1
Preparation
11
8.2
Jigs attachment
12
8.3
12
8.4
8.5
Measurement of the first stage shell plate and clean out door connection
17
8.6
19
8.7
20
8.8
20
8.9
22
SECTION IX
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ATTACHMENT ASSEMBLY
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23
SECTION X
Column erection
10.2
10.3
Welding
:
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10.1
SECTION XI
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11.1
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11.2
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SECTION XIII :
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
30
e) Welding teamwork
30
30
g) Welding electrodes
30
30
i)
Tack Welding
31
j)
31
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14.3
Welding criteria
14.4
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: INSPECTION MANUAL
34
15.1
General Items
34
15.2
35
15.3
36
36
38
SECTION XV
15.5
32
39
39
39
39
39
Other Inspections
40
40
40
15.6
Leakage Testing
40
15.7
41
15.8
41
15.9
41
15.10
41
15.11
43
Tables
1. Permissible undercutting
33
36
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Figures
1. Levelness check points on the existing foundation
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15
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17
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18
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19
21
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I.
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SCOPE OF WORK
This manual covers the fabrication, erection, installation, sand blasting and painting, inspection and
testing of welded steel storage tank.
II.
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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.
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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)
(2)
Completion of basic inking at 0, 90, 180, and 270 on concrete of tank periphery
(3)
(4)
(5)
(6)
(7)
(8)
Clean-out-door position
(9)
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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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)
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
(c)
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VII.
7.1
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(a)
(b)
Mark-off the reference line, weld the backing strip on the central and peripheral bottom plates
as shown below.
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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(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.
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7.4
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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Typical example
7.5
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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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.
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)
(d)
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8.1
Preparation
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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)
(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)
Typical Example
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Jigs Attachment
After marking-off the shell plate inside diameter, attach jigs for fitting shell plates as shown below.
8.3
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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8.4
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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(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.
Note : The space between jigs and between spacers should be determined regarding the plate size,
warp due to welding, etc.
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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.
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8.5
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)
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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.
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(c)
8.6
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.
(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
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(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)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
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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(b)
Vertical and circular joint of weld on shell plates will have complete penetration with no
undercutting.
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8.9
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(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.
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)
(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)
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.
X.
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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10.2
10.3
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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Note : Take over columns, girders, and rafters by using a rolling tower.
XI.
11.1
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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11.2
XII.
(d)
(e)
Way of putting roof plates in order apply correspondingly to manual of arrangement procedure
of lap welded bottom plates.
(b)
Weld will be carried out toward the outside from the center in principle
(c)
(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.
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)
(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)
(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)
(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)
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)
(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.
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.
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
PROCEDURE MANUAL
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(i)
Tack Welding
(j)
1.
2.
3.
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.
(k)
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
PROCEDURE MANUAL
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(l)
(m)
1.
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.
(n)
14.3
Shell attachments are defined as surface attachments, such as fit-up equipment, angle,
clips, and stair treads.
2.
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.
Welding criteria
(c)
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Max. acceptable
Undercutting
1/64 inch in depth
1/32 inch in depth
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
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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)
(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.
PT. MULTI FABRINDO GEMILANG
PROCEDURE MANUAL
2)
15.2
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Whenever doubts are arisen during the inspection, such doubts will be discussed with
personnels in charge.
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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.
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15.3
(a)
(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.
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
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
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(b)
Master-proc/Tank/Fabr-c.wrd
Face difference at the joint section of longitudinal and horizontal joint of the shell
plates should be as follows.
PT. MULTI FABRINDO GEMILANG
PROCEDURE MANUAL
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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
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)
(d)
Check for the groove angles and the root gap tolerance should be within the value
shown in the following figure.
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(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.
Master-proc/Tank/Fabr-c.wrd
Height of weld
2.4 mm or less
3.0 mm or less
Reinforcements :
Place to which the radiographic examination is
applied
1.5 mm or less
15.4
15.5
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Other inspections
(b)
(c)
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.
15.7
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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
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
15.9.1 Method
(a)
(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.
Master-proc/Tank/Fabr-c.wrd
15.10
(b)
(c)
(d)
(e)
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
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(2)
Apply soap and water solution, or forming agent, on the weld surface to be tested,
approximately 30 inches of the seam.
(3)
(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
15.11
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Master-proc/Tank/Fabr-c.wrd
ATTACHMENT A
Master-proc/Tank/Fabr-c.wrd