CV DAFFA ANGGA PERDANA

FABRICATION & TESTING PROCEDURE

Document Number:
DAP-FAM-P-00004

WORKSHOP
JALAN KEBAYUNGAN TAPOS NO.17
DEPOK, JAWA BARAT

Prepared by Reviewed by Approved by Date

Jan. 13, 2023

Rev. 0
QC Inspector Production Coordinator Project Manager
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Revision History

Rev. No. Rev. Date Revised Content Remark

0 Jan. 13, 2023 Established
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CONTENTS

1.0 Scope

2.0 Applicable Code, Standard, Specification and Drawing

3.0 Scope of Work

4.0 Requirement for Material

5.0 Quality Control Requirement during Fabrication

6.0 Fabrication Tolerance

7.0 Radiography Examination for Welded Joints

8.0 Liquid Penetrant Examination for Welds

9.0 Visual Examination

10.0 Hydrostatic Testing

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1. Scope

This specification covers the requirement regarding fabrication of all pressure vessel
which require ASME “U & R” Certification Mark Stamp.

2. Applicable Codes, Standard, Specification and Drawing

2.1. Codes and standard (current edition)

a. ASME Section VIII Div. 1
b. ASME Section II Part A, C, D
c. ASME Section V
d. ASME Section IX
e. NBIC part 1,2 & 3

2.2. Customer Document

2.2.1. Specification to be clearly documentation in sequence number revision
and titles
2.2.2. Drawing (Latest revision)

Drawing No Revision Title

2.3. MFG’s Documents

2.3.1. Drawings (Latest revision), shall include but not limited to
- Weld Detail
- General Arrangement
- Nozzle Details
- Shop Drawing

2.3.2. Design Calculation

With regard to MDMT, it is required that calculation that to be made to
inspect that inspect test of material (shall be applied), for pressure vessel.
This to be guided by:
- Section VIII Div. 1 : UG-20 & UCS-66

3. Scope of Work
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Scope of Work
A. Shell body
To be clearly specify include the opening fittings, appurtenances, base/ support
structures.
B. Accessories-Name Plate
C. Others
- Lifting lug with pad
- Pressure test with water
- Saddle pad
- Blind flange, bolt nuts and gasket.

The inspection report shall consist of following documents:

Part 1

a. Quality control manual

b. Material certification, identification & Traceability
c. Welding procedure specification
d. Personnel qualification
- Welder certificates & NDE practitioners.
e. Site queries/ non conformances

Part 2

f. NDT/ welding map

g. Welding summarized sheet
h. Non Destructive test report
- Radiography Testing Reports
- Dye Penetrant Test Report
i. Visual examination reports
j. Dimensional control report
k. Pneumatic test report
l. Manufacturer data report
m. Rubbing mark of name plate and ASME certification mark stamp
n. OneCIS Insurance Company – Final Factual Certificate/ Release Note

4. Requirement for Material.

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4.1. All of material for main portions such as shells, heads, nozzle neck and flanges
shall conform to the requirement of Section II part A, C & D, Section VIII Div. 1,
and ASME B16.5, B16.9, B16.11, B36.10M, NBIC part 1,2 & 3.
4.2. Authorized Inspector Agency
One CIS Insurance Company is nominated as shop authorized inspection party.

5. Quality Control Requirement during Fabrications.

5.1. Qualification of Welding Specification

Qualification requirement to be applied during fabrication of the pressure vessel
shall be referred to the QC Standard Procedure.

5.2. Quality Control Requirement

QC Requirement to be applied during fabrication of the pressure vessel shall be
referred to the Inspection Test Procedure.

5.3. Authorized Inspector Agency

OneCIS Insurance Company is nominated for authorization of inspection
services.

Notes :
Welded Joint Category
For U stamp, section VIII Div. 1
Welded joint category shall be referred to ASME Section VIII Div. 1, para UW-
3, as follow:

Category A
- Longitudinal welded joints within the main shell, communicating chambers,
transitions in diameter, or nozzles;
- Any welded joint within a sphere, within a formed or flat head, or within the
side plates of a flat side vessel;
- Circumferential welded joints connecting hemispherical heads to main shells,
to transition in diameters, to nozzles or to communicating chambers.

Category B
- Circumferential welded joints within the main shell, communicating
chambers, transition in diameter, or nozzles;
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- Any welded joint within a sphere, within a formed or flat head, or within the
side plates of a flat side vessel;
- Circumferential welded joints connecting hemispherical heads to main shells,
to transition in diameters, to nozzles or to communicating chambers.

Category C
- Welded joints connecting flanges, Van stone Laps, Tube sheets, or flat heads
to main shell, to formed head, to transition in diameter, to nozzles or to
communicating chambers;
- Any welded joint connecting one side plate to another side plate of flat sided
vessel of a flat side vessel.

Category D
- Welded joints connecting communicating chambers or nozzles to main
shells to sphere, to transition in diameter, to heads, or to sided vessels, and
those joints connecting nozzles to communicating chambers, (for nozzles at
the small end of a transition in diameter, see category B).
- Reviewing of films shall be finished before hydrostatic test.
- Penetrant Test may be applied when MPI is impracticable.
- UT will be as an alternative of RT, when hand placing of film cassette is
impracticable. Any UT will be followed with MPI, on root and capping
(reinforcement).

6. Fabrication Tolerance.

The Fabrication tolerances for pressure vessel shall be in accordance with the
following items:
6.1. Minimum Thickness of fabricated materials:
For U Stamp, Section VIII Div. 1 paragraph UG-27, UG-32
Ordered material thickness shall have enough margin for reduction during
fabrication such as thickness reduction during forming and no cast that the
thickness at the final fabricated condition reduced to below minimum required
thickness is allowed.

6.2. U Stamp. Section VIII Div. 1

Forming tolerance (UG-80)
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6.2.1. Out of roundness of shell

The difference between the maximum and minimum inside diameters at
any cross section shall not exceed 1% of the nominal diameter at the
cross section under consideration.
When the cross section passes through an opening or within 1 ID of the
opening measured from centre of the opening, the permissible
difference in inside diameters given above may be increased by 2% of
inside diameter of the opening. When the cross section passes through
any other location normal to the axis of the vessel, including head to
shell junctions, the difference in diameters shall not exceed 1%.

6.2.2. Tolerance for Formed Heads (UG-81)

The inner surface of a torispherical or ellipsoidal head shall not deviate
outside of the specified shape by more than 1.25% of D nor inside the
specified shape by more than 0,625% D, where D is the nominal inside
diameter of the vessel shell at point of attachment. Such deviation shall
be measured perpendicular to the specified shape and shall not be
abrupt. The knuckle radius shall not be less than that specified.
The skirt of head shall be sufficiently true to round so that the difference
between the maximum and minimum diameters hall not exceed 1% of
the nominal diameter.

6.3. Alignment Tolerance (UW-33) and Center line Alignment (UW-31)

6.3.1. Alignment of section at edges to be butt welded shall be such that the
maximum offset is not greater than the applicable amount listed in table
W-33 of ASME VIII Div. 1 where is nominal thickness of the thinner
section at the joint.
6.3.2. Any offset within the allowable tolerance provided above shall be faired
at a three to one taper over the width of the finished welds.

TABLE UW-33
Section Thickness, Joint Categories
(mm) A B, C & D
Up to 13 include ¼t ¼t
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Over 13 to 19 Include 3 mm ¼t
Over 19 to 38 include 3 mm 5 mm
Over 38 to 51, include 3 mm 1/8 t
Over 51 Lesser of 1/16 t or Lesser of 1/8 t or
10 mm 19 mm

6.4. Reinforcement of Weld Joint

a. U Stamp, section VIII Div. 1 UW-35
The reinforcement on each side of all butt welded joints to be radiographed
shall not exceed the following thickness listed in the following.
1.0 TABLE UW-35
Maximum Reinforcement, mm
Material Nominal Thickness,
Circumferential Joints in
(mm) Other Welds
pipe and tubing
Less than 2.4 2.5 0.8
2.4 to 4.8, include 3.0 1.5
Over 4.8 to 13, include 4.0 2.5
Over 13 to 25, include 5 2.5
Over 25 to 51, include 6 3
Over 51 to 76, include 6 4
Over 76 to 102, include 6 5.5
Over 102 to 127, include 6 6
Over 127 8 8

6.5. Fabrication tolerance of Weld Bevel

U Stamp section VIII Div. 1 paragraph UW-13
The fabrication tolerance of weld bevel shall be prepared in accordance with
detailed fabrication drawing and shall be complied UW-13 of ASME Section VIII
Div. 1

7. Radiography Examination for Welded Joints.

7.1. Radiography Testing procedure

Radiography testing procedure shall be referred to QC standard procedure.
7.2. The following welded joints shall be examination using radiography
- Longitudinal joint of shell (LS1)
- Circumferential Joint (CH1 & CH2)
- Longitudinal Joint of Nozzle Manhole (NLS1)
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7.3. Acceptance Criteria

A. U Stamp Section VIII Div. 1 paragraph UW-51
Indication shown on the radiographs of weld and characterized as
imperfections are unacceptable under the following condition and shall be
repaired:
a. Any indication characterized as crack or zone of incomplete fusion or
penetration.
b. Any other elongated indication on the radiograph which has length
greater than :
- For t up to 0,75”
- 0,333 t for t from 0,75” to 2,25”
- For t over 2,25”
Where t is the thickness of weld excluding any allowable reinforcement.
c. Any group of aligned indication that have an aggregate length greater
than t in a length of 12t, except when the distance between the
successive imperfections exceeds 6L where L is the length of the
longest imperfection in the group.
d. Rounded indication in excess of that specified by the acceptance
standard given in Appendix 4 of ASME Section VIII Div. 1

8. Liquid Penetrant Examination for Welds.

8.1. Method and technique examination shall be referred to be the QC Standard

Procedure.
8.2. The following weldments subject to Liquid Penetrant Test :
Weldment on manhole including pad
Weldment on nozzles N1, N2, N3
Weldment on Saddle to Shell
Weldment on support saddle

8.3. Acceptance Standard (Refer to Appendix 8 Sect. VIII Div. 1).

All surface to be examined shall be free of:
a. Relevant linier indication
b. Relevant rounded indication greater than 3/16 inch
c. Four or more relevant rounded indication in a line separated by 1/16 inch or
less (edge on edge)
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d. An indication of an imperfection may be larger than the imperfection that

causes it; however, the size of the indication is the basis for acceptance
evaluation.

9. Visual Examination.

9.1. Visual examination shall be carried out a according to QC Standard procedure.

9.2. Examination for welded surface condition
The existence of harmful defect such as crack, undercut, crater, overlap and etc.
for welds shall be examined/ confirmed by visual.
9.3. Visual examination for vessels
The existence of abnormal condition and harmful defect such as structure of
vessels, deformation by welding, surface defect and etc. shall be examined/
confirmed by visual.
9.4. Acceptance Standard
a. All welded surfaces to be examined shall be free of
- Undercut greater than 0,5 mm
- Overlaps
- Cracks
- Crater (to be finished smoothly)
b. Orientation, elevation & design for nozzles, external and etc. to be attached
to the vessel is attached as per specification drawing.
c. No excessive deformation by welding
d. No harmful defect such as surface defect, foreign matter turns up and etc.
e. Contents describe on name plate is corrected drawing.

10. Hydrostatic Testing

10.1. Hydrostatic testing shall be carried out according to QC standard procedure.

10.2. The pressure vessel subjected to a hydrostatic test pressure, which at every point
in the vessel is at least equal to 1.3 times the MAWP (UG 99).
(The MAWP may be assumed to be the same as the design pressure when
calculations are not made to determine the maximum allowable working
pressure.