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SHOP FABRICATION PROCEDURE

GASOLINE & ENGINE OIL TANK

Table of Contents

1. General
1.1 Scope
1.2 Drawing
1.3 Materials
1.4 Welding
1.5 Inspection
1.6 Painting
2. Shop Fabrication Procedure
2.1 Shell Plate
2.2 Head Plate
2.3 Manhole and Nozzle conecction
2.4 Other Accessories
3. Fabrication Inspection Procedure
3.1 Dimention Inspection Check
3.2 Tolerance Dimention
3.3 Bevel Inspection Check
3.4 Curvature Inspection Check
4. Test Inspection
4.1 NDT Inspection
4.1.1 Liquid Penetrant Test
4.1.2 Radiography Test (Spot)
4.2 Hydrostatic Test & Pneumatic Test
5. Painting
5.1 Painting

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1. General
1.1 Scope
The scope of this procedure is to explain / describe the minimum
requirements for making tanks and tank components in meeting drawing
specifications in accordance with ASME Standard sec. VIII div.1.

1.2 Drawing
All shop fabrication drawing shall be carried out in accordance with
Engineering drawing.

1.3 Material
All material shall comply with Engineering drawing and applicable client
specification.

1.4 Welding
Welding procedures spesification (WPS) for fabrication will be examined by
the project owner and all welding must be done in accordance with the
approved WPS and performed by welders (Welder) qualified according to the
requirements of ASME Section IX.

1.5 Inspection
Inspection shall be carried out in accordance with Shop Inspection Procedure
Specification.

1.6 Painting
Painting at shop shall be carried out in accordance with Painting
Specification.

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2. Shop Fabrication Procedure

2.1 Shell Plate
- Cutting and edge preparation shall be done with cutting planer or
automatic cutting machine and automatic beveling machine.
- All damage such as pop-outs, deep burn serrations shall be repaired by
grinding
- After edge preparation shell plates shall be cold rolled to the curvature in
accordance with fabrication drawing.
- The weld edge shall free from oil, dust, scale, water and other foreign
materials.
- Fabrication such as fitting, welding, shall be carried out after the clearance
from inspection authority.
2.2 Head Plate
- Material for head plates must be marked according to plan drawings and
must be cut with a cutting planer or an automatic cutting machine
- The connection with welded to the head material must be done before it is
formed
- The surface area to be welded must be cleaned to remove the crust, rust,
dust, paint, oil etc. to prevent welding defects.
- Welding must be re-gouged from the opposite side after some welding,
welds area are deposited from the inside and outside.

- On the gouged side must be checked with 100% penetration liquid test
before welded
- Forming by pressing must be done after permission from the inspection
authority with reference to the design in the drawing
2.3 Manhole and Nozzle Connection
- Neck plate for Manhole shall be cut with cutting planer or automatic
cutting machine according to the drawing, after the beveled edge is made,
the plate must be cold rolled.
- The connection plates must be welded then the flanges attached to the
manhole neck.
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- Nozzle pipe shall be beveled end with pipe cutter or grinder, and flange
shall be welded to nozzle pipe.
- Flanges face to be covered with a suitable cover to protect from damage
during handling, fabrication and transportation.

All the fabrication and welding activities shall be carried out after the stage
wise inspection wherever required.

2.4 Other Accessories

Other accessories shall be fabricated completely in accordance with drawing.

3. Fabrication Inspection Procedure

3.1 Dimention Inspection Check
Tank wall (shell plate) before roll should be measured to ensure that the
material is still on the tolerance permitted in the shop drawing.

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3.2 Tolerace Dimention

Table tolerance.

Description Tolerance

The length L1 and L2 +2.0/- 2.0 mm

Width W1, W2, W3 +2.0/- 2.0 mm

Differences center line (diagonal) D1, Less than or equal to 3.0 mm

D2

3.3 Bevel Inspection Check

Visual inspection should be done at an angle of beveling the edge of plate
surface, this checking is done after the beveling process is complete.

* Single V groove

* Square groove

* Single Bevel

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3.4 Curvature Inspection Check

Curvature measurements be done using the sweep board.

4. Test Inspection
4.1 NDT Inspection

4.1.1 Liquid Penetrant Test

Liquid penetrant examination of the following items shall be carried out
in accordance with ASME code sec. VII Div. 1 and shall be carried out
in accordance with Shop Inspection Procedure Specification.
4.1.2 Radiography Test (Spot)
Radiolography (spot) acceptance standard shall be in accordance with
ASME code sec. VII div. 1 and shall be carried out in accordance with
Shop Inspection Procedure Specification.
4.2 Hydrostatic Test and Pneumatic Test
Hydrostatic, Pneumatic or Leak Test shall be instructed in detail as approved
and shall be carried out in accordance with Inspection and Test Procedure
Specification.

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5. Painting
- Surface preparation shall be visually inspected after sand blasting or wire
brushing or other mechanical descaling according to the reference standard
required
- The primer coat of paint shall be applied immediately after surface
preparation.
- The surface prior to paint shall be clean, free of dust and sand and dry.
- Dry film thickness shall be checked with coating thickness meter.

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