Doc. No.

WSM-PSP-02
PREFABRICATION STRUCTURAL Rev. 0 11/03/19
PROCEDURE Page 1 of 10

PT. WISESA MANDIRI

PREFABRICATION STRUCTURAL
PROCEDURE

WSM-PSP-02

11/03/19 0 Issued for Approval MKY MKY AA

Date Revision Revision Description Prepared Checked Approved

 Doc. No. WSM-PSP-02
PREFABRICATION STRUCTURAL Rev. 0 11/03/19
PROCEDURE Page 2 of 10

Revision Summary

Date Revision Revision Description Prepared Checked Approved

11/03/19 0 Issued for Approval MKY MKY AA

 Doc. No. WSM-PSP-02
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PROCEDURE Page 3 of 10

INDEX

1 SCOPE AND PURPOSE ................................................................................................................ 4

2 REFERENCE DOCUMENTS .......................................................................................................... 4
3 DEFINITIONS AND ABBREVIATIONS ........................................................................................... 4
4 RESPONSIBILITIES ....................................................................................................................... 4
4.1 Engineering ........................................................................................................................ 4
4.2 Planner ............................................................................................................................... 4
4.3 Supervisor .......................................................................................................................... 5
4.4 Quality Control ................................................................................................................... 5
5 PREFABRICATION PROCEDURE .................................................................................................. 5
5.1 General ............................................................................................................................... 5
5.2 Material Preparation.......................................................................................................... 5
5.3 Manual Cutting .................................................................................................................. 5
5.3.1 Cutting and Profiling .................................................................................................. 5
5.3.2 Bevelling ..................................................................................................................... 6
5.4 Preassembly and Fit Up...................................................................................................... 6
5.5 Dimensional Control/Fit Up Inspection ............................................................................. 6
5.6 Welding .............................................................................................................................. 6
5.7 Visual Weld Control ........................................................................................................... 7
5.8 Non Destructive Testing ..................................................................................................... 7
5.9 Post Weld Heat Treatment (If Required) ........................................................................... 8
5.10 Storage Area....................................................................................................................... 8
5.11 Handling of Materials......................................................................................................... 8
6 ATTACHMENT............................................................................................................................. 9
6.1 Flowchart of Fabrication Process ....................................................................................... 9
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1 SCOPE AND PURPOSE

The scope of this document is to outline the fabrication process flow of work for each
material (Plate and Linear). The procedures purposes is to provide guidance on general working
procedures and operating methods to perform fabrication work, that will become a standard
reference for all fabrication activities on prefabrication workshop which includes:
 Material optimization (Material flow, Material traceability)
 Fabrication quality (Cutting quality, Measure accuration)
 Production time optimization (Plan and Schedules, Work Priority, Machine Capabilities)
Referring to this procedures is expected to produce an optimum fabrication system to
ensure every production process can be run properly, smoothly and directionally.

2 REFERENCE DOCUMENTS
WSM Internal Procedure and Documents

WSM-WP-01 Visual Inspection

WSM-WP-02 Repair Procedure
WSM-WP-03 Tack Welding Procedure
WSM-DP-01 Dimensional Control Procedure
WSM-PP-01 Painting Procedure

3 DEFINITIONS AND ABBREVIATIONS

Contractor PT. WISESA MANDIRI
NDE/NDT Non Destructive Examination/ Non Destructive Testing
Shop Drawing A drawing used for pipes fabrication, detailed with all information
necessary for all fabrication work.

WPS Welding Procedure Specification

CLIENT Owner of the Project

MTO Material Take Off
MRF Material Request Form
MIR Material Inspection Request
MRR Material Receiving Report

4 RESPONSIBILITIES
4.1 Engineering
Engineering is responsible to verify the completeness and correctness of the shop drawings
which should be used as a reference for the fabrication activity. Engineering also responsible to
issue material take off for material preparation purpose.

4.2 Planner
Planner is responsible for keeping every production process can be run according to the
plan that has been made based on schedule so the production activity can be run on time.
Planner should be able to provide availability of data that support activity like a data of material
that are dimension, material type, material grade, material thickness in order to guarantee the
traceability for each project based on shop drawing.
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4.3 Supervisor
Supervisor should be responsible to execute every fabrication activity based shop drawing
also conducted as per approved procedure, achieve desired quality as per required by
spec/client expectation. Supervisor should give feedback to Engineering and planner if they are
encounter problems during the fabrication process.

4.4 Quality Control

QC Inspector is responsible for checking the quality and correctness of the material that
has been cut and fit against the shop drawing dimensionally, to ensure the end result of fitting
and weld joint process is within acceptance range of the specification, to arrange for Client
Inspection (if required) and arranging NDT work. QC also responsible to arrange any kind of
test/examination as per required by specification/code such as MPI before weld, PWHT, Heat
straightening, Marking, etc.

5 PREFABRICATION PROCEDURE
5.1 General
The shop drawings (Mark drawing, Welding map, Sub-assembly drawing) should be used
to record all QA/QC requirements (e.g. Material traceability, Mark and Position number) and
accompany the material along the entire fabrication process.
Method for workshop progress tracking and material traceability other than above can be
used, such as using a Work Progress Sheet which shall be in daily bases.

5.2 Material Preparation

All material fittings should be prepared according to MRF (issued by Engineering or
Supervisor). Exact quantity to be released from material store. Material specification shall follow
approved shop drawing and other supported document.
Below are the standard check list for material and fittings:
 Check the dimension (length, width and thickness) for plate and linear materials.
 Check obtain nominal diameter and schedule number for pipe materials.
 Record down the heat number.
 Check for any defect: pitting, buckling, flattening, ovality, etc.
(corrective action for any defect found shall be managed and liaise with quality control
team)

5.3 Manual Cutting

Manual Cutting is divided into several prefabricated parts, according to the material types
to meet the progress that has been determined, Oxy-Acetylene cutting torches for carbon steel
and plasma cutting torches for stainless steel . Manual Cutting process that can be done is
cutting and profiling, bevelling.
5.3.1 Cutting and Profiling
5.3.1.1 Plate Cutting and Profiling
Plate cutting and profiling will be performed on oxy cutting or plasma cutting and reference
to the shop drawing that have been issued by engineering. Plates cutting and profiling in
prefabrication area.
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5.3.1.2 Pipe Cutting and Profiling

Pipe Cutting and profiling will be performed on oxy cutting, plasma cutting, or grinding
machine and profiling machine, and reference to the shop drawing that have been issued by
engineering. Pipes cutting and profiling in prefabrication area.
5.3.1.3 Beam Cutting and Profiling
Beam Cutting and profiling will be performed on oxy cutting or plasma cutting and
reference to the shop drawing that have been issued by engineering. Beams cutting and
profiling in prefabrication area.
5.3.2 Bevelling
Bevelling will be performed on portable machine or equivalent. Bevel parameters should
follow and as per required by the WPS for correct root and edge facing. Main bevelling process
will be done on bevelling machine and reference to the shop drawing that have been issued by
engineering.

5.4 Preassembly and Fit Up

Preassembly activities and fit up work (fit up work) will be done in the fabrication area. All
preassembly process must reference to the shop drawing that have been issued, and following
the sequence if necessary. Machining fit up work should be done in the area near the machines,
and should be in good environment to maintain the material quality. Fitter foreman and
supervisors are responsible to execute every activity based on shop drawing also conducted as
per approved procedure.
Work flow for preassembly and fit up work will be:
1. Place the material in correct places according to working type and area.
2. Align material and fittings based on shop drawing.
3. Check the alignment result with welding gauge for misalignment, root gap, etc.
4. Tack weld on the material if necessary as per applicable tack weld procedure.
5. Clean the joint preparation material, without changing the size and the accuracy of the
measure.
6. Forman fill the workshop progress sheet.

5.5 Dimensional Control/Fit Up Inspection

A dimensional control inspection shall be carried out by dimensional controller or surveyor
to ensure the cutting materials are fabricated as per shop drawing. This step should be done
same in the preassembly material. In case any fault/discrepancies, comments for repair work
shall be directly given to the fitter team, which later will be the feedback for engineering.
Parameters need to be checked and acceptance criteria should follow QC inspection procedure.
Project supervisor and foreman need to check below parameters internally before
superintendent rise Request for Inspection to QC department:
 Check the correction of dimension (length, width and thickness) for plate and linear
 materials.
 Check obtain nominal diameter and schedule number for pipe materials.
 Check the gap of welding.
 Check for any defect: pitting, buckling, flattening, ovality, etc.

5.6 Welding
Welding process in prefabrication area divided into several sections according to each
requirement. Welding shall be perform manually, welder will be using type of welding SMAW
(Shielded Metal Arc Welding), FCAW (Flux Cored Arc Welding) and GTAW (Gas Tungsten Arc
Gas). The welding work shall be carried out as per approved WPS. Welder has to be certified
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welder in accordance with the tertiary needs. During the welding process, foreman of welder
should constantly monitor the welding process to ensure application of WPS on the welding
process.
Work flow for welding:
1. Welding work should be done in the same preassembly work took place.
2. Welders need to ensure that weld preparation joint are clean and free of all extraneous
matter such as grease, dirt, scale, rust, water etc, that may affect the weld quality.
3. Conducts preheat and interpass temperature as per WPS.
4. Conduct welding work as per WPS.
5. Fill workshop progress sheet.
6. Fill welding follow up sheet.

5.7 Visual Weld Control

After dimensional check and welding, a visual weld inspection shall be carried out to verify
the quality of weld result. The visual weld examination shall be carried out by QC by involving
the client. Procedure for inspection, acceptance criteria and others requirement for welding
inspection shall follow QC’s Procedures.
1. Workshop Superintendent/Supervisor request to QC and inform the client to conduct a
visual welding inspection by attaching previous fit-up dimensional and quality report.
2. The inspection may be conducted in the welding area (fabrication area).
3. QC inspector performs the visual weld inspection and sees by client.
4. If any weld defect found, QC inspector shall mark and inform the welder team immediately.
5. Perform weld repair work (if any) as per weld repair procedure.
6. In case of un-repairable weld defect, welder team shall coordinate with fitter team to
reassembly the defected weld joint.
7. After successful inspection (fit-up + visual inspection), welders should fill workshop
progress sheet and welding follow up sheet, also identify on the job, QC acceptance
marking.
8. The data will be record by QC team and client.

5.8 Non Destructive Testing

The NDT shall be carried out to ensure that only a good weld joint will continue through
the Post Weld Heat Treatment or assembly process. Most of NDT are MPI/UT test unless stated
otherwise by the specification or codes. The requirement of NDT shall follow Client specification
or international code and standards. X-ray also can be done inside prefabrication area by
following safety procedure.
Workflow for this work:
1. Workshop Superintendent/Supervisor request to QC for conduct an NDT by attaching
previous fit-up and visual welding inspection report.
2. The inspection may be conducted inside or outside prefabrication area (depending on
requirement).
3. If conducted inside, Supervisor, QC and Safety team prepared material and the area near
the material by following safety procedures.
4. QC arranges MT/MPI work.
5. QC arranges UT work
6. NDT (MT/MPI and UT) result obtained.
7. When the weld joint are found failed during NDT, identify the defects in marking and bring
the defected material back to fabrication area (if performed outside prefabrication area),
welder supervisor and welder team have to directly carried out repair work, fill welding
follow up sheet.
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8. After successful inspection, identify the visual inspection acceptance with marking.
Supervisor should fill workshop progress sheet and welding follow up sheet.
9. QC department record the final obtained result and issued to the supervisor if required.

5.9 Post Weld Heat Treatment (If Required)

PWHT will be done using portable equipment in an area inside or outside the fabrication
area as per designated later.
Work flow for PWHT work as follow:
1. Workshop Superintendent/Supervisor request to QC department for conduct a PWHT
work.
2. PWHT work may be conducted in PWHT area or fabrication area.
3. Arrange weld joint as per shop drawing (welding map) for PWHT preparation.
4. Prepare the PWHT equipment.
5. Conduct PWHT as per required by WPS/PWHT Procedure.
6. Remove the PWHT equipment.
7. PWHT result obtained.
8. QC department record the final obtained result and issued to the supervisor if required.
9. Supervisor fills up the workshop progress sheet.

5.10 Storage Area

Fabricated material shall be storage in good environment to maintain material quality. For
plate, beam and other linear material (rectangular hollow section, square hollow section, and
angle bar), it should be based by using wooden block with 100/200mm minimum thickness to
prevent distortion during the buildup.
For pipe material, it should be storage on wooden bar from the ground or on fully surface
covered with wood to prevent distortion during the buildup and wood wedge to avoid material
rolling on floor (safety purpose). For prefabrication/preassembly item (nodes, padeye, etc.) will
be placed transverse/longitudinally position and based with wooden bar at each lower end to
prevent bevel damage, during the storage.

5.11 Handling of Materials

Handling of materials should not cause any damage on the materials itself. Few methods
to handle the materials are:
1. Forklift, use for taking out material from storage area, lifting materials and transfer
materials. Special protection for the fork should be used for exotic materials.
2. Mobile crane/overhead crane and lifting equipment should be used nylon slings, for exotic
materials separate set of slings should be used for each type of materials.
3. Trailers should be used protection floor/crates/support for fabricated pipe spools and
exotic materials.
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6 ATTACHMENT
6.1 Flowchart of Fabrication Process
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