SPECIFICATION

FABRICATION PROCEDURE

FABRICATION PROCEDURE
FOR MACHINERY & MECHANICAL EQUIPMENT

B 13-04-2017 Issued for Review

A 01-02-2017 Issued for Review
PRE CHK APP
REV DATE DESCRIPTION
CONTRACTOR
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITTEN
AUTHORIZATION OF PT. WIJAYA KARYA PERSERO Tbk.

PROYEK PEMBANGUNAN PABRIK FERONIKEL HALMAHERA TIMUR (P3FH)

Contract Number : 430/92/DAT/2016 Item No :

Document No. : Revision

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REVISION REMARKS SHEET REVISION REMARKS

SHEET
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36 ATTACHMENT
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REVISION SHEET DESCRIPTION

NO PAGE SUBJECT DESCRIPTION OF CHANGE REV.

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TABLE OF CONTENT

TABULATION OF REVISION SHEET.......................................................................................................2

REVISION SHEET DESCRIPTION........................................................................................................... 3
1.0 GENERAL...................................................................................................................................... 6
2.0 PURPOSES.................................................................................................................................... 6
3.0 SCOPE, DOCUMENTS, APPLICATION STANDARDS, AND CODES ..........................................6
3.1 SCOPE......................................................................................................................................................6
3.2 PRIORITY OF DOCUMENT...................................................................................................................6
3.3 APPLICABLE STANDARDS AND CODES .........................................................................................6
4.0 MATERIAL ..................................................................................................................................... 7
5.0 SHOP DRAWING .......................................................................................................................... 7
6.0 SHOP FABRICATION ................................................................................................................... 7
6.1 STRAIGHTENING UP OF THE STEEL ...............................................................................................7
6.2 MARKING ...............................................................................................................................................8
6.3 CUTTING ................................................................................................................................................8
6.4 DRILLING ................................................................................................................................................8
6.5 ROLLING .................................................................................................................................................9
6.6 FIT-UP ......................................................................................................................................................9
6.7 WELDING ................................................................................................................................................9
6.7.1 WELDING ELECTRODE CONTROL ...........................................................................................9
6.7.2 TACK WELDING ...............................................................................................................10
6.7.3 FULL WELDING ............................................................................................................... 11
6.7.4 WELDING JOINT CLEANING ...........................................................................................11
6.8 INSPECTION AND TEST PLAN ...............................................................................................11
6.9 PAINTING ............................................................................................................................................. 11
6.10 PACKING .............................................................................................................................................. 11

7.0 ATTACHMENT............................................................................................................................. 00
ATTACHMENT-1 (ATTACHMENT TITLE)...............................................................................................00
ATTACHMENT-2 (ATTACHMENT TITLE)...............................................................................................00

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1.0 General.
.1 Upon checking a drawing, confirm the structure, dimensions and matching condition of the mating
piece of each part sufficiently.
.2 For a part to be required to be installed on site, consider which dimension should be adjusted on
site and investigate the site condition carefully before installation.
.3 In case of construction or repair by adjusting on site without a drawing or with a simple drawing,
be inform of the condition sufficiently and if there is any question, be sure to ask our engineer.

2.0 Perposes.
This Fabrication Procedure covers the material, shop drawing, shop fabrication and welding of
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equipments and parts that are regarded as necessary to accomplish the quality required by the
customer.

3.0 Scope.
.1 Scope.

This procedure details the requirement for the fabrication of equipment and part to be fabrication /
manufacturing for the following project.

Project Name : PROYEK PEMBANGUNAN PABRIK FERONIKEL.

HALMAHERA TIMUR (P3FH).
Customer : PT. ANTAM (Persero).
Location : East Halmahera Regency, Nort Maluku Province - Indonesia.

.2 Priority of Document.
Unless otherwise specified, documents related to fabrication procedure and
inspection shall be be treated in the following order of priority :

a. Applicable law and regulation.

b. Purchase specifications.
c. Inspection item list or inspection and test plan (ITP).
d. Individual inspection and test procedures.
e. General procedure for shop inspection and test.

.3 Applicable Standards and Codes.

The standards and Codes to be applied for design, manufacture and construction :

1. API : American Petroleum Institute (U.S.A)

2. ASTM : American Society for Testing and Material.
3. ASME : American Society of Mechanical Engineers
4. ANSI : American National Standards Institute.
5. AISI : American Iron and Steel Institute.
6. ISO : International Standard Organization.
7. JIS : Japanese Industrial Standard.
8. JEC : Japanese Electromechanical Committee Standard
9. JEM : Japan Electrical Manufacture’s Association.

4.0 Material.

4.1 Material.
The material shall be new and selected for the purpose for which it intended to be used
and shall be in accordance with client’s specification / purchase specification / Mill
Certificate / Batch Number.

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4.2 Shape.
All steels to be used shall be in correct shape without any harmful defects or considerable rust
and perfectly true to thickness throughout and out of winding.

.0 Shop Drawing.
Supplier / Fabricator shall provide all required shop drawings by themselves in reference with
client design drawings or PT. Siko Techno design drawings and issue for PT. Siko Techno
approval prior to proceeded fabrication. Consider to compact / simple delivery and easy to install
on fields.

.0 Shop Fabrication.

.1 Straightening Up of The Steel

The Steel may get distorted or may bend after handling operations, therefore before attempting
father fabrication the matrial should be straightened.
The distorted steel shall be straightened up prior to fabrication depending on the degree of strain.

Repair procedure of straightening :

This procedure is provided of carbon steel plate. This procedure is applicable for
material as following :

i. Group Number II (ASTM A572 ect).

ii. Group Number I (ASTM A36, A283 Gr.C or JIS G-3101 / SS-400, ect).

There are two Types of repair for straightening.

Normally Hot and Cold Straightening is not allowed. When the Hot Straightening is applied, the
hardness check shall be done to make sure the material heated is still complied with the
mechanical properties.

1. Hot Straightening.
During Hot Straigtening, heat is introduced into the work piece by means of a burner or
electrically. The surrounding cold material obstructs the expansion of heat and the materials
is consequently, upset in the heat area due to a decrease of the yield point.

The strinkage resulting from the subsequent cooling cannot counter balance the upsetting
deformation because of the increase in strength which has occureed mean while, so that
tensile stresses result in the areas which cause a strenghtening effect.

Guidelines for Hot Straightening :

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a. For straightening with pointed heat the flame is directly calmy onto the sheet surface and
withdrawn immediately after bright red heat has been obtained.
b. The heated area must be clearly defined against their cold surrounding in order to obtain
the desired up setting effect.
c. Large deformations should be dealt with especially carefully.
d. Straightening should not be performed over the welding seam but in the sheet at certain
distaince from the weld seam.
e. The maximum temperature of heated areas shall not exceed 1100°F (600°C). For other
quenched and tempered steel nor 1200°F (650°C) for other steels. Accelereted cooling
of steel above 600 ˚F (315˚C) shall be prohibited.

2. Cold Straightening by beating out.

By this method, the shrink welding area is beaten out by hammering.

.2 Marking.
1. Marking shall be properly done by using full scale tape. Full scale tape mean is roll meter,
eg : Roll mater with range ; 0 ~ 5 mtr Lenght, 0 ~ 10 mtr Lenght, 0 ~ 20 mtr Lenght,

2. Component marks shall be marked in steel paint and various color shall be used in order to
clearly differentiate the various type of steel used.

3. Application of the center punch shall be minimized except for those areas where marking can
completely erased afterwards by means of drilling, coping or welding.

4. Marking shall not be be used for the outer face to be bent or the parts which become easily
defective.

.3 Cutting.
Steel plates shell be cut by automatic gas cutting, base saw cutting machine and
shearing machines.

.4 Drilling.
1. Drilling of members shall be drilled accurately in accordance with the marking.
2. Hole shall be made by drilling; punching of hole shall only be permitted if the plate’s thickness
is not exeeding 10 mm.
3. All burst shall be removed by grinding.

4. Hole for bolt shall not be more than 2 mm greater in diameter, unless otherwise specifically
required by design.
5. Not permited make hole with gas

.5 Rolling.

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1. Rolling process shall be done according the specification design requirement and detail
drawing (Cutting Plan).
2. The rolling line must be controlled by rolling gouge according sizes and length which are
specified by design.
3. After finished process, the material must be minimized distortion.

.6 Fit Up.

1. Prior to assembling, marks of each part, dimensions, and degree shall be checked with shop
drawing.

2. Plates and and components which are to be welded shall be assembled, aligned, and
retained in their position for welding to ensure that the dimensions and tolerance specified
are maintained during welding and that the required shape of the assembly is obtained after
welding.

3. In assembling, special care shall be taken in order to avoid misalignment in the direction of
plate thickness and bending from joint parts due to angular distortion.Touch face of the parts
to be fillet welded shall be brought into as close contact as practical.

4. Assembling skid shall be strong enough to remain firmed during fabrication and be kept
horizontal.

5. In case where the member is required to be tack - welded to the jig, it shall be carefully
gouged and finished smooth by by grinding after completion of fabrication or welding works.

.7 Welding.

All welding shall be carried out in an approved environment and if necessary, additional protection
may be required. Prior welding surface of part shall be dried.

.7.1 Welding Electrodes Control.

1. Check specification requirement for consumables type to be used.

2. Incoporate type into consumable list for submission to client for

3. Proposed consumables shall be compatible and relevant to the proposed or

approved WPS and PQR.

4. Upon approval or the consumables list, project control or warehouse section shall
there by issue requisition order to purchasing section to fullfill order.

5. Upon receive of the welding consumables shall be conduct.

Inspection for conformity of the followings :

a. Welding consumables shall be received in their original fully sealed unopened

container, packege or cartons.
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b. All manual type electrodes shall be indentfiable up to the time of usage,

electrode being distinguished by their individual relevant coding.

c. Low hydrogen electrodes that are shall be purchased in hermatically sealed

container. Immediately after opening the hermetically sealed containers
electrode shall be baked in oven baking at a temperature of 300 ~ 350°C for 30
~ 60 minutes follow manufacturer recommendation upon opening or removal
from the package. And the permissible atmospheric exposure of low hydrogen
electrode shall not exceed 4 ( four ) hours if the electrode exposure hydrogen
electrode shall not exceed 4 ( four ) hours if the electrode exposure

d. Wire spools for automatic and semi automatic processes shall be stored in an
approved storage space or cabinet with the supplier wrapping not removed and
shall remain clearly identifiable up to the time of use age un-identifiable wire
shall not be use.

e. Flux shall be supplied and store in accordance with the manufacturer’s

instruction.

f. For low hydrogen electrodes, each welder shall use dryer during welding at
temperature minimum 100°C or as per manufacturing recommendation.

.7.2 Tack Welding.

1. Tack well shall be one by welding Procedure Specification and qualified welder.

2. Tack weld shall not have short bead as supplied drawings. The length of tack weld
shall not be less than 50 mm which ever is smaller for ordinary steel and 80 mm for
high strength steel.Pitching shell be 150 mm as standard practise. When
determining the size and number of tack welds for a specific job, should consider
the thicknesses of the metals being jointed and the complexity of the object being
assembled.

3. Tack weld shall be deemed to be the same quality as the final welds.

4. Tack welding shall be applied to the reverse side of the back gouged part as a rule,
however should it not be practical for structural reason, the alternative methode
shall be carefully used in consideration that tack weld should become part of the first
pass of weld.

5. In case any crack should occer in the part where tack welding has been applied, it
shall be gouged up the bottom of deposited metal and rewarded..

.7.3 Full Welding.

1. Full welding shall be done by WPS and qualified welder / certificated welder.

2. The size and lengh of welds shall be no less than those specified by design

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requirement and detail drawing.

3. Weld sequence shall be such as weld minimizes distortion and shrinkage.

4. The direction of welding shall be from points where the part are relatively fixed in
position with respect to each other toward point having a greater relative freedom
and movement.

5. Material thickness more than 25 or less but specific did preheating.

.7.4 Welding Joint Cleaning.

1. Welding surface and adjacent surfaces shall be through cleaned of loose rust, mill
scale, foundry scale, burn metal or accumulation of slag or oil, grease, paint, dirt,
moisture, protective coatings or other material which may detrimentally affect, the
weld the weld. These “matters” shall be removed by means of flame, wire brushing,
grinding other suitable method.

2. After pass or run of welding, all slag be removed from the weld surface.

3. After cleaning care shall be taken to avoid subsequent contamination due to dirt or
condensation on surface which have been left in the assembled but not welded
condition Inter run cleaning shall be carried out by suitable means so as to prevent
inclusion of impurities in the weld. Visible defect such as crack, cavities and other
deposition welding faults shall be removed before deposition of further metal.

4. At each any layer of weld, After finish weld, welding surface shall be cleaned of slag,
spatter, dirty and other material by grinding or chipping.

.8 Inspection and Test Plan.

Refer to Inspection and Test Plan

.9 Painting.

Refer to Painting Procedure

.10 Packing.

Refer to Packing Proceddure.

.0 Attachment.

.1 Scope.

a. The standard is used as acceptance criteria of production process and erection at PT. SIKO
Techno.

b. The standard is used if the Owner specification is not required.

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c. If the specification is not match with the drawing, so reference what is used in fabrication is
the drawing.

.2 Penerimaan Material ( Incoming Material )

All of materials’s tolerance refer to JIS and ASTM

.2.1 Plate

a. Thickness ( Tebal ) .

b. Width ( Lebar ).

c. Length ( Panjang ).

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d. Flatness ( Kerataan )

Note :

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.2.2 Strip Plate

.2.3 Round Bar

.2.4 Pipe’s ( Pipa ).

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.2.5 CNP.

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.2.6 Square Pipe’s ( Pipa Kotak )

.2.7 Siku, UNP ( Angle, UNP )

a. Dimensi ( Dimension ).

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b. Kelurusan / Kerataan ( Straightness / Flatness ).

.2.8 H-Beam

a. Dimensi ( Dimension ).

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b. Kelurusan / Kerataan ( Straightness / Flatness ).

.2.9 Baut & Mur ( Bolt & Nut )

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.3 Fabrication
Fabrication tolerance refer to ASTM Standard ( EN ISO 13920 )

.3.1 General

a. Length ( Panjang ).

b. Crosswise ( Diagonal ).

c. Angle ( Sudut ).

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d. Flatness / Straightness ( Kerataan / Kelurusan )

.3.2 Machining ( Pemesinan ).

.3.3 Shelll and Duct.

a. Offset and Vertical Joint.

b. Staggering of shell plates.

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c. Shell and Duct Diameter.

.3.4 Bolt Holes.

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.3.5 Column, Girder and Beam.

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.3.6 Assembly.

General tolerance refer to EN ISO 13920

a. Frame of Conveyor

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b. Column

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c. Base Frame

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d. Girder.

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e. Pulley Frame.

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f. Hopper Chute.

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g. Stringer Stand.

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h. Edge Cutting.

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.4 Welding.

.4.1 Welding Standard.

a. Start End Welding.

b. Edge Welding.

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c. Weld Access Hole

d. Cap Plate.

.4.2 Welding Joint Tolerance.

Welding joint tolerance refer to AWD D1.1 and ASME Section IX

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.4.2 Welding Dimension Tolerance.

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Inspection Item and Standard for Main Support.

This Item and Standard shall be applies only for Main Support.

a) Measuring Points.

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b) Tolerance of Product.

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