FABRICATION & ERECTION PROCEDURE

FOR STORAGE TANK

HSD 2 X 1100 KL

TABLE OF CONTENTS
1. SCOPE
2. REFERENCE
3. GENERAL REQUIREMENTS
4. NON DESTRUCTIVE EXAMINATION
5. FABRICATION AND ERECTION PREPARATION
6. FABRICATION AND ERECTION THE BOTTOM PLATE
7. TESTING AND COMMISSIONING
8. PROTECTIVE COATINGS
9. FINAL INSPECTION

1.

SCOPE

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FABRICATION & ERECTION PROCEDURE

FOR STORAGE TANK
HSD 2 X 1100 KL

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This procedure describes about fabrication and erection for Bottom plate of Storage Tanks that
is manufactured by PT. Barata Indonesia.

2. REFERENCE
2.1. API Standard 650, Welded Steel Tank for Oil Storage.
2.2.

JIS ( Japan Insdustrial Standardl )

2.3. ANSI ( American National Standard Institute )

2.4. ASME Section IX Welding and Brazing Qualification
2.5. AWS D.1.1. Structural Welding Code - Steel

3.

GENERAL REQUIREMENTS
3.1. MATERIAL IDENTIFICATION
Marking personnel shall assign all identification marking, which consists of material
specification, item number, heat number or plate number for all parts of Storage Tanks.
If the markings of material identification be lost because of next manufacturing process,
the marking shall / wall be re-transferred by the marking personnel.
Where the service conditions prohibit die stamping for material identification and when
so specified by Owner or for the piece of material under inch ( 6 mm ) in thickness,
the marking shall be marked with steel marker so that each piece of material will be
positively identified.
The Quality Inspector shall be responsible for verification of the material identification
marking transfer which was made by the shop personnel.

3.2. MARKING AND TRANSFER IDENTIFICATION

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The marking personnel shall lay out the item or part to be cut on the intended material
and stamp the applicable marking on the each item or part by using the blunt-nose die
stamps accordance with cutting plan and applicable drawing.
All identification material and part shall be marked completely

and The Quality

Inspector shall be inspected before cutting to be done.

3.3. CUTTING PLAN

The cutting plan is lay out marking of parts. It is made for marking guide to avoid
the mistakes to use a material and the material eficiency.

3.4. CUTTING AND EDGE PREPARATION

The edge preparation of weld joint shall be accordance with applicable drawing.
Weld joint preparation may be made by machining, grinding and thermal cutting
provided the prepared weld joint surface shall be uniformly smooth, free of all loose
scale and slag accumulation and preferably ground back to bright metal finish.
If preheating is specified for welding it shall also applied to the material prior to thermal
cutting.
Prior to welding, the surface up to 1 inch from the edge of the welding groove for
ferrous shall be clean and free from oil, rust, scale, slag, grease and other foreign
material which is detrimental to welding.

3.5. BENDING AND FORMING

Plate or pipe for the other purpose may be bent with radius of bend which will result in
a bend surface free of cracks.

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Bending is the first process in shell / wall fabrication and to simplize to get a radius
accordance with drawing on the ends of plate.
The ends of plate for shell / wall is bent with radius accordance to applicable drawing
before forming ( rolling ).
Forming is process to form cylindrical shell / wall plates and head plates from steel
plate with radius accordance to applicable drawing..
Form the shell /wall plates so that it will overlap approximately 1t ~ 3t of plate on
circumference.

3.6. WELDING
All tack welding and welding of temporary attachments shall

use the Welding

Procedure Specification ( WPS ) and Qualified Welder.

Temporary attachments used during fabrication shall be the same as the base material,
these tack weld shall be removed after welding and the attachment is ground smooth
and flushed with the surrounding surface.
Repair of tack weld and welding may be made with the same procedure and the same
type of electrode or filler wire that would be used for root pass.

3. 7. FILLER MATERIAL AND CONTROL

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Filler material for welding shall be compatible with the base material and shall comply
with those specified in the ASME Boiler and Pressure Vessel Code Section II Part C
for Welding Rods, Electrodes and Filler Metals
Storage and atmospheric exposure limits of low hydrogen electrode for Shield Metal
Arc Welding ( SMAW ) Shall comply with the requirements of AWS D1.1 Section 4.
Filler materials in the following conditions will be considered damaged and shall not be
acceptable for inclusion in the works.
- Material that are damaged or pitted.
- Electrodes which are dirty, damp, contaminated with oil.
- Electrodes with flux separated from the wire.
- Bare and flux core wire with rusts which can not be removed by light sanding.
- All flux wire electrodes contaminated with oil or water.
- Electrodes which have exceeded atmospheric exposure limits.
Bare and flux core wire that becomes dirty may only be used, if cleaned and restored to
a bright surface prior to use.
Welders shall not be issued or allowed to carry more than one type of electrode or filler
metal and one time except that a qualified welder is specifically assigned to make a
weld involving two processes.
Unused welding rod shall be returned and stored in the proper storage area for welding
electrodes. Damaged electrodes as defined shall be discarded.

3.8. WELDING PROCEDURE SPECIFICATION, PROCEDURE QUALIFICATION

RECORD AND WELDER QUALIFICATION

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Welding Procedure Specification ( WPS ) and Procedure Qualification Record ( PQR )

shall conform to the requirements of ASME Section IX Welding and Brazing
Qualification and ANSI B 31.3
Welders or Welding Operators Qualification have been certified by MIGAS. See
Qualified Welder List.
The using of Welding Procedure Specification ( WPS ) shall be shown on Welding
Map, if required.

3.9. WELDING REPAIRS

Unacceptable discontinuities shall be completely removed by chipping, gouging,
grinding or other authorized methods ( for the type of material being repaired ) to clean,
sound metal and the excavated area shall as a minimum be visually examined to assure
complete removal.
Weld repairs shall be made using the same WPS used for the original weld, or other
approved welding procedure.
The repaired area shall be re-examined using the same inspection method which
detected the original defect.
Only two attempts will be allowed to repair any one defective area. If defects are
detected after second attempt, further repairs shall not be allowed without approval
from the Owner.

4.

NON DESTUCTIVE EXAMINATION ( NDE )

4.1. GENERAL REQUIREMENTS

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NDE methods, acceptance criteria and additional general requirements shall be in

accordance with the applicable fabrication code and this specification.
Visual examination shall be by personnel certified to AWS QC 1. All other NDE shall be
by personnel qualified to Level II or Level III requirements of SNT-TC-1A of the
American Welding Society for Non Destructive Testing.
Visual examination shall be performed before other NDE.
Radiographic examinations

required

shall

be

done

in

accordance with the

requirements of the appropriate fabrication Code and shall comply with the acceptance
criteria of that code.
Radiographic examination no required by the fabrication Code but required by this
specification shall be in accordance with the requirements of ASME Section V. Article
2. The result shall comply with the reference with the acceptance criteria.

4.2. VISUAL EXAMINATION

The examination procedure shall be in accordance with the requirements and methods
specified in ASME Code, Section V, Article 9 and this specification.
Surfaces of all finished welds shall be visually inspected.

4.3. MAGNETIC PARTICLE EXAMINATION

The examination procedures shall be in accordance with the requirements and methods
specified in ASME Code, Section V, Article 7 and this specification.

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Base material 1 inch on each side of the weld shall also e include in the examination of
welds.

4.4. LIQUID PENETRANT EXAMINATION

The examination procedures shall be in accordance with the requirements and methods
specified in ASME Code, Section V, Article 6 and this specification.
Base material 1 inch on each side of the weld shall also e include in the examination of
welds.

4.5. ULTRASONIC EXAMINATION

The examination procedures shall be in accordance with the requirements and methods
specified in ASME Code, Section V, Article 5 and this specification.
Base material 1 inch on each side of the weld shall also e include in the examination of
welds.

4.6. RADIOGRAPHY EXAMINATION

The examination procedures shall be in accordance with the requirements and methods
specified in ASME Code, Section V, Article 2 and this specification.
The length of any single slag inclusion or elongation shall not be more than twice the
thickness of the weld and the cumulative length of slag inclusion in any 6 inches long
weld not be more than 4 times the thickness of the weld. The width of a slag inclusion
shall not exceed 0.125 inch or 0.5 weld thickness whichever is smaller.

5.

FABRICATION AND ERECTION PREPARATION

5.1. Man power and equipment preparation and coordination.

FABRICATION & ERECTION PROCEDURE

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HSD 2 X 1100 KL

5.2. Review and check

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Fabrication documents, the technical document and drawings

completely.
5.3. Check the completely of the material procurements ( Main Material, Consumable
Material, Supporting Material for Storage Tanks ) and documentation to avoid material
loosing and defect ( Repair, if required ) according to material specification of technical
documents and drawings.
5.4. Prepare the tools and equipment for fabrication and erection of Storage Tank ( Mobile
Crane, Welding Machine and Accessories, Stairs, Safety equipment, Chain Block,
Support, etc. )
5.5. Check and prepare the foundation area for The Storage Tanks according to specification
and drawing.
5.6. Make reference lines on the foundation area to simplize the fabrication and erection
storage tanks as follow :
- The high of foundation
- The level of foundation
- The center line and other reference lines.
5.7. Pre fabrication of main structure, Sub assembly of nozzle, Hand Rail, Roof Tank
Structure and Frame, Forming of Shell plates and Roof Plates, Supports and other
parts.

6.

FABRICATION AND ERECTION THE STORAGE TANKS

6.1. Bottom Plates Instalation
After finishing the foundation preparation and inspection, the fabrication and erection of
storage tanks can be began. The mobile crane and welding machine is not placed on the
foundation area to avoid the foundation defects.

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6.1.1. Install the bottom plates and annular plates should be done with carefully and
than fit up. Sub assembly of annular plates is made in the work shop and than
installed on the sit, if possible to minimize the site working and avoid the
foundation defect. Welding is done according with drawing, welding map and
WPS.
6.1.2. Make the center line for reference. And than place the bottom plates to be began
from center according to the drawing lay out of bottom plates.
6.1.3. Fit up and tack weld the bottom plates connection according with WPS, tack
weld length 40 mm and each 400 mm.
6.1.4. After fit up and tack weld the bottom plates is finish and dimension inspection.
And than followed with welding according to drawing, weld map and WPS to
be began from center of bottom plates lay out ( with welding sequence as
follow : C1, C2 - Cn and than L1, L2 - Ln ).
For acceleration and keep the fabrication and erection schedule, shell plates of
storage tanks can be began to be installed on the annular plates, but annular
plates should be finish to be welded and Inspected ( Visual, Dimension
Inspection and NDE ) according with Inspection Test Plan.
And the reference for shell plates instalation is center line of foundation

6.1.5. Cutting the bottom plates and annular plates is done after finish weld to control
dimension tolerance.

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6.2. Shell Plates Instalation

Instalation and welding sequence of shell plates as follow :
6.2.1. Install and set up the 1st shell plates on the annular plate, support plates and
tack weld. And than install and tack weld the support plates for placing the 2nd
shell plates.
6.2.2. Install and set up the 2nd shell plates on the 1st shell plates, support plates and

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6.2.3. tack weld. And than install and tack weld the support plates for placing the 3 rd
shell plates.
6.2.3. Dimension inspection for install and set up result.
6.2.4. Welding long seam ( LWL of the 1 st shell plate ) according to drawing, weld
map and WPS.
6.2.5. Visual and dimension inspection.
6.2.6. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.2.7. Install the 3rd shell plates on the 2nd shell plates, support plates and tack weld.
And than install and tack weld the support plates for placing the 4th shell plates.
6.2.8. Dimension inspection for install and set up result.
6.2.9. Welding long seam ( LWL of the 2nd shell plate ) according to drawing, weld
map and WPS.
6.2.10. Welding circumferential ( CWL2 ) according to drawing, weld map and WPS.
6.2.11. Visual and dimension inspection.
6.2.12. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.2.13. Install the 4th shell plates on the 3rd shell plates, support plates and tack weld.
And than install and tack weld the support plates for placing the 5th shell plates.
6.2.14. Dimension inspection for install and set up result.
6.2.15. Welding long seam ( LWL of the 3rd shell plate ) according to drawing, weld
map and WPS.
6.2.16. Welding circumferential ( CWL3 ) according to drawing, weld map and WPS.
6.2.17. Visual and dimension inspection.

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6.2.18. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.2.19. Install the 5th shell plates on the 4th shell plates, support plates and tack weld.
6.2.20. Dimension inspection for install and set up result.
6.2.21. Welding long seam ( LWL of the 4th shell plate ) according to drawing, weld
map and WPS.
6.2.22. Welding circumferential ( CWL4 ) according to drawing, weld map and WPS.
6.2.23. Visual and dimension inspection.
6.2.24. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.2.25. Install the 6th shell plates on the 5th shell plates, support plates and tack weld.
And than install and tack weld the support plates for placing the 6th shell plates.
6.2.26. Dimension inspection for install and set up result.
6.2.27. Welding long seam ( LWL of the 5th shell plate ) according to drawing, weld
map and WPS.
6.2.28. Welding circumferential ( CWL5 ) according to drawing, weld map and WPS.
6.2.29. Visual and dimension inspection.
6.2.30. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.2.31. Install the 7th shell plates on the 6th shell plates, support plates and tack weld.
And than install and tack weld the support plates for placing the 7th shell plates.
6.2.32. Dimension inspection for install and set up result.
6.2.33. Welding long seam ( LWL of the 6th shell plate ) according to drawing, weld
map and WPS.
6.2.34. Welding circumferential ( CWL6 ) according to drawing, weld map and WPS.

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6.2.35. Welding long seam ( LWL of the 7th shell plate ) according to drawing, weld
map and WPS.
6.2.36. Welding circumferential ( CWL7 ) according to drawing, weld map and WPS.
6.2.37. Visual and dimension inspection.
6.2.38. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.2.39. Install and tack weld the angle plate on the 8th shell plate according to drawing.
6.2.40. Dimension inspection for install and set up result.
6.2.41. welding the angle plate on the 8th shell plate according to drawing, weld map
and WPS.
6.2.42. Welding joint between the bottom plate and the annular plate according to
drawing, weld map and WPS.
6.2.43. Welding circumferential ( CWL1 ) according to drawing, weld map and WPS.
6.2.44. Visual and dimension inspection.
6.2.45. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.3. Roof Tanks Instalation
Structure and plates of Roof tanks is installed with being use the center line of shell
plate for reference.
6.3.1. Install and fit up the main frame of structure of roof tanks from the center line to
the side and supported.
6.3.2. Install and fit up the stranger and the girder to the main frame of roof tanks
structure.
6.3.3. Visual and dimension Inspection according to Inspection Test Plan ( ITP ).

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6.3.4. Install the plates of roof tanks from the center according to the lay out drawing
of roof tanks.
6.3.5. Inspection the plates of roof tanks.
6.3.6. Welding and welding sequence is same with the welding sequence of shell
plates.
6.3.7. Visual and dimension inspection.
6.3.8. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.3.9. Welding repair all defects, if required.

6.4. Nozzles, Stairs, Hand Rail and Other Accessories Structure Instalation
6.4.1. Install, fit up and tack weld the sub assembly of Nozzles, Stairs, Hand Rail and
Other parts to the Storage Tanks according to Drawing, Weld map and WPS.
6.4.2. Visual and dimension inspection
6.4.3.

Welding the sub assembly of Nozzles, Stairs, Hand Rail and Other parts to the
Storage Tanks according to Drawing, Weld map and WPS.

6.3.4. Visual and dimension inspection.

6.3.5. Non Destructive Test ( NDE ) for welding result according to Inspection Test
plan ( ITP ).
6.3.6. Welding repair all defects, if required.

7.

TESTING AND COMMISSIONING

After finishing fabrication and inspection will be followed with :
7.1. Hydrostatic test
7.2. Vacuum test

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7.3. Fire Fighting.

8.

PROTECTIVE COATINGS
Protective coatings on equipment shall comply with :
- STEEL STRUCTURE PAINTING COUNCIL SPECIFICATION
( SSPC SPECIFICATION )
All equipment and surfaces that require painting shall be shop painted before delivery to site.
All surfaces, parts and equipment as bolt threads, screw ends, flange faces, etc. shall be
protected before painting.
Surfaces requiring field welding or field work, or where insulation is required may be pre
primer with the primer paint before delivery to site.
All flux, welding spatter and arc strike shall be removed and the affected area ground
smooth with a grinder.
Rough welds, undercuts, pinholes and other irregularities shall be repaired, corrected and
ground smooth.
Sharp edges, unless required for specified purpose shall be rounded off.
All spent abrasive material, dust, scale, etc. shall be removed from all surfaces by brushing
or blowing with clean, dry compressed air and vacuuming before the application of paint.
Blast cleaned surfaces shall be kept clean, free of moisture and other contaminants which
may be detrimental to the application of the paint.
The primer , intermediate and finish coat shall be different colors. And Painting repair shall
be conducted if the paint condition as follow :
- Paint thickness was not reaching the value required .
- Any damages during handling, transportation and unloading to the site.

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For above, re coating shall be done at the point of damage surfaces with extent to the
50 mm of the damage point as the following :
-

Check the damage point.

Extent to the 50 mm of those damage.

Cleaning those surfaces with power brush.

Re coating again with brush at those surfaces after suitable time.

And detail of painting specification and procedure should be shown in PAINTING

PROCEDURE.

9.

FINAL INSPECTION
The final inspection for general and main dimension of The Storage Tanks after fabrication
and erection is finish to be done. The Quality Control Department make the Manufacturing
Date Report ( MDR) and to be distributed to The Customer.