Document No. : 024/FBP/FB/1003935/11.

21
PT.SWADAYA GRAHA Revision : 0
Gresik - East Java - Indonesia 61122 Date : November 25, 2021
TECHNICAL IMPLEMENTATION MANUAL Page : 1 of 7

FABRICATION PROCEDURE

DOCUMENT NO. : 024/FBP/FB/1003935/11.21

REVISION / EDITION : 0
DATE : NOVEMBER 25, 2021
PO. NO. : PO-BBC/2021/X/004
PLAT FORM NEW FLARE PLANE OF STEEL BOTTOM GRID & HEAD STOCK
RDMP BALIKPAPAN JO
PT. PANCA DUTA PRAKARSA

REV. DATE PAGE DESCRIPTION PREP’D CHK’D APP’D

0 Nov 25, 2021 1-7 Issued for Approval Suji ef M. Fadholi

Engineering Department
Steel Fabrication Division
 Document No. : 024/FBP/FB/1003935/11.21
PT.SWADAYA GRAHA Revision : 0
Gresik - East Java - Indonesia 61122 Date : November 25, 2021
TECHNICAL IMPLEMENTATION MANUAL Page : 2 of 7

FABRICATION PROCEDURE

TABLE OF CONTENTS

Pages
1. SCOPE (3)

2. APPLIC ABLE REFERENCE (3)

3. MATERIAL (3)

4. SHOP DRAWING (3)

5. SHOP FABRICATION (3)

6. WELDING (5)

Engineering Department
Steel Fabrication Division
 Document No. : 024/FBP/FB/1003935/11.21
PT.SWADAYA GRAHA Revision : 0
Gresik - East Java - Indonesia 61122 Date : November 25, 2021
TECHNICAL IMPLEMENTATION MANUAL Page : 3 of 7

FABRICATION PROCEDURE
1. SCOPE.
The scope of work shop drawing, shop fabrication, welding, painting,
packing & delivery.
2. APPLICABLE REFERE NCES
- Appro v ed D raw ings
- As per do c. Custo m er
3. MATERIAL.
2.1. Material.
The material shall be new and selected for the purpose for which it is
intended to be used and shall be in accordance wi th Client’s
Specification.
2.2. Shape.
All steels to be use d shall be in correct shape without any harmful
defects or consid erable rust and perfectly true to thickness
throughout and out of winding.
4. SHOP DRAWING.
PT. SWADAYA GRAHA shall provide all r equired shop drawings in reference
with Clients Design Drawings and issue for Clients Approval prior to
proceed fabrication.
5. SHOP FABRICATION.
5.1. Marking.
(1) Marking shall be properly done by using full scale tape.
(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 comple tely erased afterwards by
means of drilling, coping or welding.
(4) Marking shall not be used for the outer face to be bent or the
parts which become easily defective.

Engineering Department
Steel Fabrication Division
 Document No. : 024/FBP/FB/1003935/11.21
PT.SWADAYA GRAHA Revision : 0
Gresik - East Java - Indonesia 61122 Date : November 25, 2021
TECHNICAL IMPLEMENTATION MANUAL Page : 4 of 7

FABRICATION PROCEDURE
5.2. Cutting.
Steel plates shall be cut by automatic gas cutting, band saw cutting
machine and shearing machines.
5.3. Drilling.
(1) Drilling of members shall be drilled accu rately 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 exceeding 10 mm.
(3) All burst shall be removed by grinding.
(4) Hole for bolts shall not be more than 2 mm greater in diameter,
unless otherwise specificall y required by design.
5.4. Rolling.
(1) Rolling process shal l be done according the specification design
requirement and detail drawing (Cutting Plan).
(2) The rolling line must be controlled by rolling gauge acco rding
sizes and length which are specified by design.
(3) After finished process, the material must be minimizing
distortion.
5.5. Fit Up.
(1) Prior to assembling, marks of each part, dimensions, and degree
shall be checked wit h shop drawing.
(2) Plates and components which are to be welded shall be
assembled, aligned, and retained in their position for wel ding 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, spe cial 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 sha ll be strong enough to remain firmed during
fabrication and be kept horizontally.

Engineering Department
Steel Fabrication Division
 Document No. : 024/FBP/FB/1003935/11.21
PT.SWADAYA GRAHA Revision : 0
Gresik - East Java - Indonesia 61122 Date : November 25, 2021
TECHNICAL IMPLEMENTATION MANUAL Page : 5 of 7

FABRICATION PROCEDURE
(5) In case where the member is required to be tack - welded to the
jig, it shall be carefully gouged and finished smooth by grinding
after completion of fabrication or welding works.
6. WELDING.
All welding of carbon steel, stainless steels and alloy steels shall be carried
out in an approved environment and if necessary, additional protection may
be required. Prior welding surface of part shall be dried.
6.1. Welding Electrodes Control.
(1) Welding engineer shall check contract specification requirement
for consumable’s type to be used.
(2) Incorporate type into consumables list for submission to client
for their approval. List shall include all r elevant test’s certifi cate,
classifi cation conformity certificates, etc
(3) Proposed consumables shall be compatible and relevant to the
proposed or approved WPS and PQR.
(4) Upon approval or the consumables list, project cont rol or
warehouse section shall there by i ssue requisition order to
purchasing section to fulfill order.
(5) Upon receive of the consumables by warehouse shall i nform
welding engineer to conduct inspection for conformity of the
followings :
(a) Welding consumables shall be recei ved in their original fully
sealed unopened container, package or cartons.
(b) All manual type el ectrodes shall be i dentifiable up to the
time of usage, electrode being distinguished by their
individual relevant coding.
(c) Low hydrogen electrodes that are shall be purchased
inhermetically sealed container. Immediately after opening
the

hermetically sealed container electrode shall be dried in

heated held at a temperature of least 250 o F ( 120 o C ) upon

Engineering Department
Steel Fabrication Division
 Document No. : 024/FBP/FB/1003935/11.21
PT.SWADAYA GRAHA Revision : 0
Gresik - East Java - Indonesia 61122 Date : November 25, 2021
TECHNICAL IMPLEMENTATION MANUAL Page : 6 of 7

FABRICATION PROCEDURE
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 exceed the
permissible period allocated, they shall be rebaked no more
than once.Electrodes shall be kept in m obile furnace until by
the welder.
(d) Wire spools for au tomatic and semi automatic processe s
shall be stored in an approved storage space or cabinet wit h
the supplier wrapping not removed and shall remain clear ly
identifiable up to the time of usage unidentifiable wire shall
not be use.
6.2. Tack Welding.
(1) Tack we ld shall be done by Welding Procedure Specification.
(2) Tack welding shall n ot have short bead as supplied drawings. The
length of tack weld shall not be less than 50 mm whichever is
smallerfor ordinary steel and 80 mm for high strength steel.
Pitching shall be 150 mm as standard practice.
(3) In case any cra ck sh ould occur in the pa rt where tack weldi ng has
been applied, it shall be gouged up the bottom of deposited metal
and rewarded.
(4) Tack welding shall be applied to the reverse side of the back -
gouged part as a rule, however shoul d it not be practical for
structural reason, the alternative method shall be carefully used
in consideration that tack weld should become part of the first
pass of weld.
(5) Tack welds shall be deemed to be the same quality as the final
welds.
6.3. Full Welding.
(1) Full Welding shall be done by WPS.
(2) The size and length of welds shall be no less than those specified
by design requirement and detail drawing.
(3) Welding sequence shall be such as weld minimizes distortion and
shrinkage.

Engineering Department
Steel Fabrication Division
 Document No. : 024/FBP/FB/1003935/11.21
PT.SWADAYA GRAHA Revision : 0
Gresik - East Java - Indonesia 61122 Date : November 25, 2021
TECHNICAL IMPLEMENTATION MANUAL Page : 7 of 7

FABRICATION PROCEDURE
(4) The direction of welding shall be from points where the parts are
relatively fixed in position with respect to each other toward
point having a greater relative freedom of movement.
6.4. Welding Joint Cleaning.
(1) Welding surfaces an d adjacent surfaces shall be through cl eaned
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. These “maters” shall be removed by means of
flame, wire brushing, grinding or other suitable method.
(2) After each pass or run of welding, all slag be removed from the
weld surface.
(3) After cleaning, ca re shall be take n 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 cracks,
cavities and other deposition welding faults shall be removed
before deposition of further metal.
(4) After finish weld, welding surface shall be cleaned of slag, spatter,
dirty and other material by grinding or chipping.
6.5. Pre-Heating.
Pre-heating shall be applied using elect ric heater or air with natural
gas or propane. No oxy-fuel cutting torches shall be used for
heating,rosebud torches are acceptable.

Engineering Department
Steel Fabrication Division