WATER TANK Doc. No.

: PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

Tabel of Contents
Cover………………………………………………………………………………………………………………………………………1

Table of contents…………………………………………………………………………………………………………………….2

1. SCOPE……………………………………………………………………………………………………………………………….3
2. PURPOSE…………………………………………………………………………………………………………………………..3
3. REFERENCE……………………………………………………………………………………………………………………….3
4. RESPONSIBILITY…………………………………………………………………………………………………………………3
5. METHOD OF CONSTRUCTION……………………………………………………………………………………………3
6. INSPECTION AND TESTING…………………………………………………………………………………………………6
7. PROPOSED PLANT AND MAJOR EQUIPMENT PLANT/TOOLS/TACKLES……………………………….9
8. MAN POWER…………………………………………………………………………………………………………………..10
9. QUALITY ASSURANCE & QUALITY CONTROL……………………………………………………………………10
10. SAFETY…………………………………………………………………………………………………………………………….10
11. RECORD…………………………………………………………………………………………………………………………..10
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

1. SCOPE
This procedure covers detailed activities for fabrication, erection and testing of the
Demin Water Tank and Fresh Water Tank for PLTU SINTANG 3x7 MW Project.

2. PURPOSE
The purpose of this document is to follow proper methodology to carry out the
activities in a proper sequence and requirement for fabrication, erection and testing of
Demin Water Tank and Fresh Water Tank.

3. REFERENCE
AWWA D-100, ASME sec IX, ASME sec V, Approval Drawing and book contract.

4. RESPONSIBILITY
The responsibility of implementation of this procedure rests with Construction
Manager of PT. ZUG INDUSTRY INDONESIA and PT. ADHI KARYA (persero).

5. METHOD OF CONSTRUCTION
5.1 IDENTIFICATION OF MATERIALS
Each piece of plates, fittings or any other component of tank system shall be
clearly identified by marking heat no. on the part using hard punching or paint
marking. Each weld joint shall be marked with joint Number with Welder Number.

5.2 FABRICATION WORK

All fabrication work involving material identification, marking, cutting, rolling and
welding shall be done in accordance with this AWWA D-100 and book contract.
The workmanship shall be good in every respect meeting all safety, QC & NDT
requirements, with coordination of Engeneer-In-Charge.

5.2.1 STRAIGHTENING
Any required straightening of material shall be done using method that will
not harm the stell. Minor cold straightening is permitted. Cold
straightening may be performed by hammering or preferably by rolling or
pressing. Heat may be used in straightening more severe deformations.
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

5.2.2 FINISH OF PLATE EDGES-WELDED WORK

The plates edges to be welded may be universal mill edges or they may be
prepared by shearing, machining, chipping, or by mechanically guided
oxyfuel gas or plasma arc cutting. Edge of irregular contour may be
prepared by manually guided oxyfuel gas or plasma arc cutting.

5.2.3 ROLLING
Plate shall be cold rolled to suit the curvature of the tank. Plate do not
require rolling for tank having a diameter larger than the minimum
diameter indicated in table 1 and for the plate thicknesses given therein.

5.3 ERECTION
5.3.1 GENERAL
The constructor shall furnish all labor, liability and compensation insurance,
tool, falswork, scaffolding, and other equipment necessary to erection the
tank in compliance with the contract requirement.

5.3.2 WELD
All welds in the tank and structural attachments shall be made in a manner
to ensure complete fusion with the base metal, within the limits specified
for each joint, and in strict accordance with the qualified welding
procedure specifications. Welding shall not performed when the surface of
the parts to be welded are wet from rain, snow, or ice, when rain or snow
is falling on such surface, or during periods of high wind, unless the welder
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

or welding operator and the work are properly protected. All welder or
welding operator shall test prior welding.
Contour of the surface beads shall merge smoothly into each other in all
weld. Undercutting of base metal in the plate adjoining the weld shall be
repaired, except as permitted in 6.2.
The thickness of the reinforcement of the welds on all butt joints shall not
exceed the thickness given in table 2. The reinforcement need not be
removed except to the extent that it exceeds the maximum acceptable
thickness or when required for radiographic inspections. In no case shall
the face of the weld lie below the surface of the plates being joined.

5.3.3 PREPARATION OF SURFACES TO BE WELDED

Surface to be welded shall be free from loose scale, slag, heavy rust,
grease, oil, paint and any other foreign material except tightly adherent
mill scale. A light film of deoxaluminate or equivalent spatter film
compound may be disregarded. Such surface shall also be smooth,
uniform, and free of tins, tears, and other defects that adversely affect
proper welding. A fine film of rust adhering on out or sheared edges after
wire brushing need not be removed.

5.3.4 TANK ASSEMBLY

All shell, bottom, and roof plates subjected to stress by the weight or
pressure of the contained liquid shall be assembled and welded in such a
manner that the proper curvature of the plates in both directions is
maintained.
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

Any clips, jigs, or lugs welded to the shall plates for erction purposes shall
be removed without damaging the plates, and any portion of weld beads
remaining shall be chipped or ground smooth.
The bottom Plates for elevated tanks shall be assembled and welded
together by a procedure that will results in a minimum of distortion from
weld shrinkage. The bottom plates for flat bottom tanks, after being laid
out and tacked, shall be joined by welding the joint in a sequence that the
constructor has found to result in the least distortion due to shrinkage of
the weld. Out of plane distortion equal to 1 percent of the tank radius is
considered acceptable.
Tank shall for welding in the vertical position, the progression of welding
shall be either upward or downward, according to the direction specified in
the welding procedure and used for welder performance qualification. The
shell plates shall be joined by welding the joints in a sequence that the
constructor has found to results in the least distortion due to shrinkage of
weld and that will avoid kinks at the longitudinal joints.
The maximum out of plumbness of the top of the shell relative to the
bottom of the shell shall not exceed 1/200 of the total shell height.
Roundness measured at 1 ft (0.3m) above bottom corner weld shall not
exceed to tolerances as given in table 3.

Peaking is the out of plane distortion across a circumferential weld seam,

using a horizontal sweep board 36 in (0.91 m), bending shall not exceed ½
in (13 mm).

5.3.5 MATCHING PLATES

Lap joints. The plates forming a lap joint shall be heid in as close contact as
possible during welding. In no case shell palte separation be more than
1/16 in (1.6 mm). Where plate separation occurs, the size of weld shall be
increased by the amount of the separation.
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

Butt joints. The adjoining edges of butt joints shall be aligned accurately
and retained in position during welding, so that the offset tolerances of
table 4 are not exceed in the welded joint.
Cleaning of welds. The constructor crew shall remove weld scale of slag
spatter, burrs, and other sharp or rough projections in a manner that will
leave the surface suitable for the subsequent cleaning and painting
operations. Weld seams need not be chipped or ground, provided they can
be satisfactory cleaned and painted.

6. INSPECTION AND TESTING

6.1 WELDER QUALIFICATION
Before any welding is performed, the constructor or manufacturer shall make
certain that welders or welding operators have their credentials for acceptance or
they shall be tested, after which welding may proceed.

6.2 INSPECTION OF WELDED JOINTS

Inspection of all complete joint penetration welded shall be made by spot
radiographic method except that by agreement between the purchaser and the
constructor. Inspection by radiographic methods is not recommended for butt
joints for which partial penetration weld are allowed, and shall not be required for
the following joints :
a. Welds in roof plates
b. Welds in flat tank bottom resting direciy on grade or foundation
c. Welds joining flat tank bottoms to the first rings of the tank shell
d. Welds connecting the top angle to the shell or roof
e. Welds connecting appurtenances to the tank
f. Welds connecting manhole
g. Any other fillet welds not previously included

In addition to the inspection and criteria for acceptance, the welded joints shell
comply with the following provisions, as determined by visual inspection.
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

a. For butt joints subject to primary stress due to weight or pressure of tank
contens, maximum permissible undercutting shall be 1/64 in. (0.4mm) each
side.
b. For butt joints subject to secondary stress, maximum permissiable
undercutting shall be 1/64 in (0.8 mm) each side.
c. For lap joints subject to primary stress due to weight or pressure of tank
contens, the maximum permissible undercutting shall be 1/64 in (0.4 mm).
d. For lap joints subject to secondaru stress, the maximum permissible
undercutting shall be 1/32 in (0.8 mm) deep, measured along either leg of the
weld.

6.3 NUMBER AND LOCATION OF RADIOGRAPHS

6.3.1 JOINT OF THE SAME TYPE AND THICKNESS
One radiograph or sectional segment taken in the first 10 ft (3m) of
completed joint welded by each welder or welding operator. Without
regard to the number of welders or welding operators working. One
additional radiograph or remaining major fraction thereof. The radiograph
locations selected for seam subject to primary stress shall include at least
one seam subject to primary stress, with a minimum of two junctures per
tank.

6.3.2 TANK SHELL AND WET RISER SECONDARY STRESS

Tank shell and wet riser joints of the same type and thickness based on the
thickness of the thinner plate at the joint that are subject to secondary
stress, without regards to the number of welders or welding operators
working thereon. Shall have one radiograph or sectional segment taken in
the 10 ft (3m) of completed joint. Thereafter, one additional radiograph or
sectional segment shall be taken in each additional 200 ft (60m) and any
remaining major fraction thereof. When portions of the joints have partial
joint penetration weld, the location of the radiographs or sectional
segment shall be selected from that portion of the seam containing the
complete joint penetration welds.

6.4 PROCEDURES FOR RADIOGRAPHYC TESTING

 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

Radiographic examination method shall be in accordance with ASME Boiler and

Pressure Vessel Code Sec V, Nondestructive Examination, Article 2.
Each radiograph shall clearly show a minimum of 6 in. (152 mm) of weld length
except for a jungtion of vertical and horizontal welds which shall clearly show not
less than 2 in (50mm) of horizontal weld length on each side of the vertical
intersection and a minimum of 3 in (75mm) of weld length on vertical seam.
One penetrometer shall be used for each film, to be placed adjacent to or across
the weld seam at the approximate center of the location to be examined. For
horizontal welds, the penetrometer shall be placed parallel of the weld seam.
Radiographyc Standards : section of welds shown by radiography to have any
following imperfections shall be judged unacceptable :
1. Any crack, incomplete fusion, or incomplete penetration
2. Any individual elongated inclusion having a length greater than two thirds the
thickness of the thinner plate of the joint except that, regardless of the plate
thickness, no such inclusion shall be longer than ¾ in (19 mm) and no such
inclusion shorter than ¼ in (6mm) shall be cause for rejection.
3. Any group of inclusions in line, which the sum of longest dimensions of all each
imperfections is greater than T (T being the thickness of the thinner plate
joined) in a length of 6T, except when the space between every pair of
adjacent imperfections is greater than three times the length of the longer of
the imperfections, when the length of the radiograph a less than 6T, the
permissible sum of the lengths of all inclusions shall be proportionately less
than T, provide the limits of the deficient welding are clearly defined.
4. Rounded indications in excexx of those shown as acceptable in ASME Boiler
and Pressure Vessel Code, Sec. VIII Division 1 Pressure Vessel.

6.5 TESTING
The tank shall be field tested after it is completed and before painted.
6.5.1 Flat Bottoms
The joint may be tested by the magnetic particle method. Air pressure at
vaccum may be applied to the joint, using soapsuds, linseed oil, or other
suitable material for detection of leaks. The gauge should register a vaccum
of at least 2 psi (13.8 kpa).

6.5.2 Shell, Bottom, and Roof

 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

The Tank shall be hyrostatic test (fillet water) the water shall be at proper
pressure to fill the tank to the top capacity level. The tank shall be
hydrostatically tested to a pressure of 3.000 m of water above the top of
the tank. Any leak in the shall, bottom, or roof shall be repaired.

6.6 PAINTING
After a satisfactory test has been completed, the tank shall be painted in
accordance with project spec. / book contract and painting procedure.

7. PROPOSED PLANT AND MAJOR EQUIPMENT PLANT/EQUIPMENT/TOOLS/TACKLES

 Crane 10MT/12MT capacity.
 Welding transformers/rectifiers 400 a & 600 a welding generations.
 Radiography sourse Ir 192.
 Test Pump.
 Water Pump.
 Transporting Equipment.
 Plate bending Machine.
 Pipe Bending Machine.
 Hydraulic Jack 12 MT (with power pack & accessories) and other required
equipment.
 Grinding machine.
 Gas cutting equipment.
 Vaccum pump and vaccum box with gauge
 Lifting Tools & Tackles and Derrick.
 Portable Oven.
 Measuring Tape.
 Plano Wire, Plumbob (heavy weight).
 Viewer.
 Aluminium Ladder 4 Nos.
 12v hand lamp set for all four tanks.
 Exhaust fan for all four tanks.
 DG set panel board separately for welding Rectifier and Grinding.
 Elcometer Pr.Gauge, Air Compressor etc.
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA

8. MAN POWER
AS PER REQUIREMENT

9. QUALITY ASSURANCE & QUALITY CONTROL

This shall followed and maintened with the compliance/adherence to the drawings,
procedure and code specification. Records shall be kept in the relevant check sheet
and formats duty signed by all the concerned departments.

10. SAFETY
 Safety Precautions should be followed during fabrication and erection, as per
project specification.
 Welding cables and power cables to be laid properly as per project rules and local
state government rules.
 Proper house keeping and clean condition shall be maintained in the fabrication
shop and site as per requirement.

11. RECORD
 Foundation hand over Reports (elevation and position)
 Material Certificate
 Welding Inspection Reports
 Dimension Reports
 NDT Reports
 Test Reports
 WATER TANK Doc. No. : PSG-7-PR-QA/QC-
WTFEP-31
PLTU SINTANG 3X7 FABRICATION AND Date : 3 MEI 2018
MW ERECTION PROCEDURE Revision : 2
KALIMANTAN BARAT PT.ADHI KARYA (PERSERO)-PT.ZUG Page : 2
INDUSTRY INDONESIA