FABRICATION PROCEDURE

Table of Contents

 

1. Purpose -----------------------------------------------------------------    2 of 6
   
2. Applicable Code, Standard and Specification -----------------    2 of 6
   
3. Fabrication Sequence------------------------------------------------    2 of 6
   
4. Material Receiving-----------------------------------------------------    2 of 6
   
5. Nonconforming Material----------------------------------------------    3 of 6
   
6. Receiving of Purchaser Supplied Product-----------------------    3 of 6
   
7. Material Issuing---------------------------------------------------------    3 of 6
   
8. Layout and Cutting-----------------------------------------------------    3 of 6
   
9. Transfer of Heat Number---------------------------------------------    3 of 6
   
10. Fit-up-----------------------------------------------------------------------    3 of 6
    
11. Welding -------------------------------------------------------------------    4 of 6
    
12. Control of Welding Consumable------------------------------------    4 of 6
    
13. Non-Destructive Examination----------------------------------------    4 of 6
    
14. Testing And Inspection -----------------------------------------------    4 of 6
    
15. Painting -------------------------------------------------------------------    5 of 6
    
16. Packing and Shipping preparation----------------------------------    5 of 6
    
17. Manufacturing Data Book (MDR)-----------------------------------    5 of 6
    
18. Appendix A – Fabrication Sequence-------------------------------    6 of 6
    

 

1. Purpose
   

   To describe the method Synco shall adopt for fabrication and assembly of 1440 PSI – TEST SEPARATOR 20' CSC / DNV EQUIPMENT FRAME.
   

   To ensure the products are meet with the referenced fabrication Code and client requisition.
   

   
    

2. Applicable Code, Standard and Specification
   

   All of the equipments shall be fabricated, inspected and tested in accordance with the following related specification :
   

   1. DNV 2.7-1 : 2006
      
   2. EN 12079 : 2005
      
   3. ISO 1496-1 (CSC)
      
   4. AWS D1.1 – Edition 2006
      

 

1. Fabrication Sequence
   
   1. Approval Prototype for Design Calculation and drawing by Third Party comply CSC and DNV Code.
      
   2. The fabrication sequence of 1440 PSI – TEST SEPARATOR 20' CSC / DNV EQUIPMENT FRAME.
      are as per appendix A.
      

 

1. Material Receiving
   
   1. Upon receipt of material, Store man shall spray the material with a yellow paint "hold" to await inspection by QC Inspector.
      
   2. The QC Inspector is responsible for verifying and inspecting all material to be used for Code fabrication against Packing List, P/O and applicable material specification, as follows:
      

• Material has clear identification as required by the Code (e.g., heat number, material specification i.e. grade, type and class if applicable) and traceable to material certificate when required.
  
• Contents of chemical analysis and mechanical test results on material test certificate is in accordance with the respective material specification and P/O.
  
• Material is free from defects and imperfections such as pitting, scaling, lamination, etc. which would affect the safety of the Tank.
  
• Additional examination required by the P/O had been performed (such as Non Destructive Examination, Heat Treatment, Impact Test and Hardness Test) and test certificates are available and in compliance with the Code and client's specification.
  
• Item inspected matches with the "For Construction" drawing.
  

1. All materials that have been checked by Store man and accepted by the QC Inspector shall be painted in accordance with Inspection and Test Status color-coding.
   
2. The Store man and the QC Inspector shall sign Packing List or P/O (green copy) to indicate their acceptance. P/O (green copy) together with Delivery Docket/ Packing List will be forwarded to the Account Officer to match with supplier invoice.
   
3. SYNCO shall give free access to the Authorized Inspector and/ or clients representative to verify material identification if necessary. The QC Inspector shall transmit material test certificate after his review/ acceptance to the Authorized Inspector and/ or client representative for their review.
   

 

 

1. Nonconforming Material
   
   1. The QC Inspector in conjunction with Project Manager shall raise a Material Discrepancy Advice when there is discrepancy in quantity or when material test certificate is not provided with Delivery Docket.
      
   2. The QA/QC Manager shall raise a Non Conformance Report when receiving material with no identification, defective material and material not complying with specification. Nonconformance item shall be identified with hold/ reject tags/ paint in accordance with QM-01 section 7.
      
   3. The non-conforming material shall be segregated from fabrication area.
      

   
    

2. Receiving of Purchaser Supplied Product.
   
   1. Upon receipt, purchaser supplied materials or items shall be subject to exactly the same level of inspection as SYNCO purchased items using packing list and material test certificates provided.
      

 

1. Material Issuing
   
   1. Responsibility is given to the Workshop Manager or his delegate and the Store man to dispatch and receive accepted items from secured storage area.
      
   2. Materials for specific jobs are collectively located in job areas. The Workshop Manager or his delegate shall ensure that only the intended material is used in Code fabrication. He shall check to ensure the material has been checked by the QC Inspector with appropriate color-coding and check with the drawing for correct sizes and specification.
      

 

1. Layout and Cutting
   
   1. Plate's layout for cutting accordance with the actual drawing.
      
   2. Dimension shall be verified diagonally to ensure the square ness.
      
   3. Plates, shape structural and other parts should be cut by oxygen cutting. Beveling shall be in accordance with construction drawing.
      
   4. After oxygen cutting, all slag and detrimental discoloration of material which have been molten shall be removed by grinding.
      
   5. Before cutting QC inspector shall inspect for correct material, sizes and heat number are properly transferred.
      
   6. After cutting, QC inspector shall visually inspected the cut edges for possible for laminations, shearing cracks and other imperfections.
      

 

 

1. Transfer of Heat Number
   
   1. The Workshop Manager or his delegate is responsible for transferring heat number of plates or pipes before cutting. The method of transferring heat number shall use low stress die stamping except if prohibited by client's specification or by the Code. The remaining material to be returned to stock shall be identified with material specification and heat number marked. The QC Inspector is responsible to ensure that all material is clearly identified. Material with no identification shall not be used.
      

 

 

1. Fit-up
   
   1. Items/ material that are being welded shall be fitted, aligned and retained in position during welding.
      
   2. Bars, jacks, clamps and tack welds may be used to hold the edges of parts in alignment.
      
   3. Tack welds, which are to be incorporated into the final weld, shall be visually examined for defects. If a defect is detected, tack weld shall be removed. The start and stop ends shall be properly prepared prior to continuing welding.
      
   4. Alignment during fit-up shall be maintained not to exceed Code requirements.
      

 

 

1. Welding
   
   1. Welding Procedure Map and the WPS(s) to be used for production shall be transmitted to Workshop Manager and put on the notice board in fabrication shop for easy access to the welder and welding operators.
      
   2. The Workshop Manager is responsible for assigning and supervising welders for Code fabrication. He shall ensure that the assigned welders are qualified or make arrangements for their qualification. The welder and welding operator shall ensure inspection clearance status, i.e., color coding "GREEN" before embarking on any production welding.
      
   3. Welding may be performed from single side or double side. For double side welding second side may be prepared by grinding or carbon arc gouging and finished by grinding. In-house MT/ PT are required after back grinding or back gouging.
      
   4. After completion of the weld, the QC Inspector shall examine them visually. Any comment shall be marked with chalk or felt pen on location requiring subsequent work, i.e., grinding, touch-up weld, etc. After he is satisfied with his visual examination he shall initial and date in "Welding Traceability Records" form. The QC Inspector shall also use this form to record welder no, weld/ joint no. and NDE results.
      
   5. QC Inspector shall verify weld reinforcement and undercut are not exceed Code requirements. Fillet sizes shall be in accordance with the drawing.
      

 

1. Control of Welding Consumable
   
   1. Electrodes and welding consumable receiving, storage and issuing shall be in accordance with procedure WCP-01 "Welding Consumable Control Procedure".
      
   2. Welding consumables (electrodes, wire and flux) shall be stored at temperature and humidity recommended by the electrode manufacturer.
      
   3. Covered low hydrogen electrode shall be baked/ re-dried from its original packing at temperature and period as per manufacturer recommendation.
      
   4. After baked/ re-dried covered low hydrogen electrode shall be kept in holding oven at a temperature recommended by manufacturer.
      
   5. Low hydrogen electrode shall be issued to the welders from holding oven to their individual quiver.
      

 

1. Non-Destructive Examination
   
   1. NDE shall be performed in accordance with approved "NDE Map and NDE Procedure" and ITP.
      

 

1. Testing and Inspection
   
   1. On completion of fabrication, the QC Inspector shall perform final dimensional check and visual examination of welds and all surfaces before Load and Proof test. Synco will invite Authorized Inspector and Client Inspector for final inspection before proof test for final visual and dimensional inspection.
      
   2. The Authorized Inspector shall make his final visual inspection before proof test. He shall sign and date ITP package, when he is satisfied that the 1440 PSI – TEST SEPARATOR 20' CSC / DNV EQUIPMENT FRAME meets the applicable Code requirements. The QA/QC Manager shall ensure that all NCRs are properly closed before proof test.
      
   3. Testing shall be conducted in accordance with CSC / DNV requirement
      
   4. Prototype testing include:
      
      1. 4 Lifting points test
         
      2. 2 Lifting points test
         
      3. Drop Test
         
      4. Longitudinal and lateral inertia test
         
      5. Longitudinal restraint test
         
      6. Transverse Racking
         
      7. Stacking Test
         
      8. Top Corner ISO Lifting Points Test
         
      9. Bottom Corner Lifting Points Test
         
      10. Lifting Test – Forklift Pockets
          

   
    

2. Painting
   
   1. Surface Preparation and Painting shall be conducted in accordance with approved procedure.
      

 

1. Packing and Shipping preparation
   
   1. Packing and shipping preparation shall be in accordance with procedure
      

   
    

2. Manufacturing Data Book (MDR)
   
   1. All material test certificates and inspection reports shall be compiled progressively by QC Inspector.
      
   2. The contents of MDR shall be in accordance with "Manufacturing Data Report Index - Table of Content".
      

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

   
    

Appendix A – Fabrication Sequence