CONSTRUCTION

METHOD
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CLIENT :
CONTRACTOR :
PROJECT NAME :
LOCATION :
CONTRACTUAL NO. :

0 6 Rev.

PREPARE CHECKED APPROVE CHECKED

REMAR APPROVED
REV. DATE SHT BY BY D BY BY
K
PT WIJAYA KARYA CLIENT
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REVISION SHEET

No Revision Date Remark

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TABLE OF CONTENT

1. GENERAL...................................................................................................................

2. REFERENCES............................................................................................................

3. PREPARATION..........................................................................................................

4. ERECTION STEPS....................................................................................................

4
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1. Purpose.

Construction method is a written document demonstrates the manufacture

process in fabrication and erection for Suban Condensate Storage Tank.

2. Scope.

Construction Method for Suban Condensate Storage Tank consists of:

Receiving Material
Fabrication
Material handling
Erection with Jack Up Method
Inspection or NDT (Non Destructive Test)
Pre-Commissioning

3. Receiving Material.

All material will be received at Jakarta Workshop for Suban Condensate

Storage Tank Project.
Every material received shall be inspected as follow:
Check the material status and quantities according to the description on
the delivery document.
Check the materials dimension and thickness shall be accordance to the
approved drawing.
Request for inspection to third party (if required) or client to witness
and approved the material before start the fabrication.
All the material shall accordance to material mill certificate and
recorded by Quality Control

4. Fabrication.
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All material which is required for fabrication will be fabricated at the Jakarta
Workshop and will be transported to Suban Conocophilips after fabrication
completion.
Fabrication of the tank consists of:
4.1. Fabrication of annular plate
4.2. Fabrication of bottom plate
4.3. Fabrication of shell plate
4.4. Fabrication of top angle
4.5. Fabrication of roof structure
4.6. Fabrication of roof plate
4.7. Fabrication of accessories

4.1. Fabrication of annular plate.

4.1.1. Preparation is carried out to prepare two pieces of plate are places on
the flat area and do the measurement of dimension, as well marking to
set the dimension accordance to approved drawing.
4.1.2. Make a mold that made from wooden board, where the wooden board
shall be made to the nominal outer radius of annular plate, mark the
plate with marker or used a stamp for cutting guideline.
Description Outer Radius (mm)
Condensate Tank 18,541
Fire Water Tank 6,942

4.1.3. Carried out using the cutting machine, following the marking line that
has been set.
4.1.4. The edge joint between two annular plates shall be beveled; the angle
of bevel shall accordance to the approved drawing.
4.1.5. Annular that has completed must be marked with item number and tank
number, for easy identifying and transfer the heat number of materials
4.1.6. All the fabrication process for annular plate must recorded and control
by Quality Control.

4.2. Fabrication Bottom Plate.

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4.2.1. Mark and cut the bottom plate to dimension that are according to the
approved drawing.
4.2.2. The length of lap joint or single welded lap joint between bottom plates
with minimum 30 mm.
4.2.3. The distance between shell plate and annular plate weld to the single
lap joint of annular plate and bottom plate shall be minimum 600 mm.
4.2.4. Every material of bottom plate shall be marked with the item number
and tank number, for easy identifying. And the heat number shall be
transferred and recorded by Quality Control.

4.3. Fabrication Shell Plate.

4.3.1. Prepared the shell plate on the flat surface, and do the marking
according to the dimension in the approved drawing.
4.3.2. Marking on the shell plate the width and length dimension shall be
perpendicular.
4.3.3. Recheck the dimension after cutting, also clean or grind the sharps
edges and the surface of the beveled.
4.3.4. A mold shall be made accordance to the inner radius of shall plate. The
mold is a guide for implementation of rolling.
Description Inner Radius (mm)
Condensate Tank 18,441
Fire Water Tank 6,858

4.3.5. Roll the entire shell plate and examine by using the mold.
4.3.6. Every material of shell plate shall be marked with item number and
tank number, for easy identifying. And heat number shall be transferred
and recorded by Quality Control.
4.4. Fabrication Top Angle.

4.4.1. Checked dimension of top angle to ensure that the material was in
accordance with approved drawing.
4.4.2. Tack weld together two top angle surface to surface adjacently,
afterward that angle that has been joined may proceed to roll.
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4.4.3. During the rolling process, the radius of angle shall be checked with the
same mold that is used for the shell plate.
4.4.4. After rolling was done, remove the tack weld and grind the tack
residue. Recheck again the radius to make sure its still meet the radius
according to the approved drawing.
4.4.5. Every material of top angle shall be marked with item number and tank
number, for easy identifying. And heat number shall be transferred and
recorded by Quality Control.

4.5. Fabrication Roof Structure.

4.5.1. Roof structure consists of center drum, roof rafter, gusset plate, and
roof girder.
4.5.2. Check the material dimension, further more can be marked and
fabricated to appropriate dimensions accordance to approved drawing.
4.5.3. The main concern is also the type and form of roof structure, for the
Suban Condensate Storage tank Project is using the cone roof type.
4.5.4. Every material of Roof structure shall be marked with item number and
tank number for easy identifying. And heat number shall be transferred
and recorded by Quality Control.

4.6. Fabrication Accessories.

4.6.1. The accessories on the tank is generally consist of manhole, nozzle,

stairway, hand railing, post hand railing, name plate, pipe support and
etc.
4.6.2. Before precede to the fabrication, first is checking the material
dimension, furthermore can be marked and fabricated to appropriate
dimension accordance to approved drawing.
4.6.3. For the possibility of connection must be adjusted to actual condition,
and can be carried out at the time of erection. At the time of fabrication
is given more dimension tolerance.
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4.6.4. Every item of accessories shall be marked with item number and tank
number for easy identifying. And the heat number shall be transferred
and recorded by Quality Control.
5. Material Handling.

5.1. Before all the materials will be transported to the site, all the material
will be sand blasted and painted with the primer paint, to protect the
materials from the corrosions during delivery and standby at the lay
down area.
5.2. All the material will be packed and tied with the metal straps, but the
weight for each pack will calculated to the capable capacity of the
crane at site
5.3. For materials such as bottom plate, annular plate, shell plate, roof plate
shall be packed and strap accordance to the tank number for easy
identifying.
5.4. For all material such as bottom plate, annular plate, shell plate and roof
plate will be stacked and between each plate shall be placed a thin
wood to protect the surface of material contact each other.
5.5. Shell plate materials shall be seated on the skid, to protect radius of
shell plate from deformation.
5.6. Nozzle material shall be transported inside the wooden box, and the
surface of the flange shall be covered with wooden board, to protect
surface of flange from any damage.
5.7. At the lay down area, the materials shall be placed accordingly with the
priorities.
5.8. The material will be transported with the trailer trucks, the weight of
load shall be not exceeded the capacity of the trailer truck.

6. Erection with Jack Up method

6.1. Checking the foundation.

6.1.1. Before annular and bottom plate being erected the orientation
and the level on the foundation shall be checked, which the data
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on the orientation and level of the foundation shall provided by

the civil contractor.
6.1.2. After orientation of the foundation is found follow the approved
for construction drawing, than pull a wire on the position 0 to
180 and on the position 90 to 270 to get a center point of the
foundation.

6.2. Erecting annular plate

6.2.1. Measuring from the center of the foundation to the outside

radius of the annular.
6.2.2. Annular plate shall be erected one by one until all annular plate
linked.
6.2.3. Fit up and tack weld on the joint of annular plate before
welding to the joint. Check the outer radius to be sure if the
radius according to approved drawing.
6.2.4. During the fit up, on the annular surface shall be placed a jig to
hold on during the welding, to prevent plate from deformation.
6.2.5. Next step is welding on the annular plate joint, which can be
started before bottom plate is finish being fit up.
6.3. Erecting bottom plate

6.3.1. Erection bottom plate shall be started from the center of bottom
plate, which follows the center point of the foundation that has
been marked.
6.3.2. The orientation of bottom plate shall be accordance to the
approved drawing.
6.3.3. The other bottom plate shall be arranged from the center to
annular plate, distribute all the bottom plate to its position.
6.3.4. During the fit up on the bottom plate the overlap between
bottom and bottom to annular shall be measured. The overlap
need not exceed 25 mm.
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6.3.5. Once the fit up on the bottom plate were done, the welding on
the joint shall be carried on by following the bottom plate
welding sequence.

6.4. Erecting shell plate.

6.4.1. For the Suban condensate storage tank project, the method of
erecting shell plate by jacking up method.
6.4.2. Jack up method is erecting the shell plate from top to bottom.
6.4.3. At Suban condensate storage tank project the specification as:

Condensate tank Thickness (mm)

Shell 1 14
Shell 2 12
Shell 3 9
Shell 4 8
Shell 5 8
Shell 6 8
Shell 7 8
Shell 8 8

Fire water tank Thickness (mm)

Shell 1 9
Shell 2 8
Shell 3 6
Shell 4 6
Shell 5 6
Shell 6 6
Shell 7 6

6.4.4. Erecting shell plate for condensate tank shall be started from
shell 7 and shell 8, and for fire water tank shall be started from
shell 6 and shell 7.
6.4.5. Make a shell inside diameter line and checking line on the
annular plate, which the checking line shall be 100 mm from
the shell inside diameter line.
6.4.6. The support beam shall be placed on the annular plate before
erecting the shell plate.
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6.4.7. The number of support beam needed for each condensate tank
is 38 nos. and for fire water tank is 14 nos.(Figure1)

(Figure 1)

6.4.8. Erect the shell plate one by one until its complete ring, by
following shell inside diameter marked on the annular plate.
6.4.9. Place a support on the inside of the shell plate to make sure the
plate is standing straight. (Figure 2)
6.4.10. After all shell plate is supported, fit up on the shell plate before
any welding to the joint.
6.4.11. Inspection on the shell shall be carried out such as plumbness
and roundness, to make sure the shell plate in the right position
before continuing to next shell.

(Figure 2)

6.5. Erecting top angle and roof structure and roof plate.

6.5.1. After all two shell plate have been erected and welded, the next
process is erecting the top angle. (Condensate tank shell 7 and
shell 8, and for Fire water tank shell 6 and shell 7)
6.5.2. Check the roundness of the top angle before start the welding.
6.5.3. During the welding process on the top angle, the temporary
column for support the center drum shall be installed; the
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temporary column shall be tied with wired slings to prevent its

falling to any direction. (Figure 3)
6.5.4. Temporary column shall not be removed until entire roof rafter
is connected.
6.5.5. The gusset plate shall be installed to the shell plate by
following the orientation on the approved drawing.
6.5.6. Erect the roof structure such as roof rafter and roof girder, and
shall be bolted to the gusset plate and center drum.
6.5.7. All bolted rafter and girder shall be check the bolt tension with
the moment key tool, to prevent if there are any loose bolt.
6.5.8. Once the roof structure is completed and checked, continue
erecting the roof plate.
6.5.9. The orientation of the roof plate shall accordance to the
approved drawing.
6.5.10. Fit up the roof plate with a temporary jig, the function of the
temporary jig is used to prevent the roof plate from deformation
during the weld.
6.5.11. After the roof plate done fitted and welded, the temporary
column for center drum shall be removed before continuing
erected the next shell plate.

(Figure 3)

6.6. Erecting the next shell plate.

6.6.1. Erecting the next shell plate shall be done by hydraulic jack.
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6.6.2. The components of hydraulic jack are:

Hydraulic Pump attached to the hydraulic oil tank
Control valve (manifold) to synchronization output to each hydraulic jack.
Rubber hoses
Hydraulic jack Cap. 30 Ton/unit
Jack up column
Support bracket
Mild steel profile (H beam 150 x 150 and H beam 100 x 100)
6.6.3. The number of hydraulic jack needed for the Suban condensate
storage tank project is:

Description No. of Hydraulic Jack

Condensate Tank 1 28
Condensate Tank 2 28
Fire Water Tank 10

6.6.4. Set the jack up column, support bracket, control valve and
hydraulic jack on the inside of tank.
6.6.5. The support bracket shall be welded to the shell plate. Support
bracket welded in between two jack up column.
6.6.6. Put the hydraulic jack under the support bracket.
6.6.7. Connected the entire hydraulic jack with the rubber hose to
control valve.
6.6.8. The hydraulic jack shall be seated on the Mild steel profile.
6.6.9. The inside shell plate that will be welded with support bracket,
on the outside of the shell plate shall be installed a stiffener
using CNP 150 x 50 x 100, this stiffener only installed on the
shell plate thickness less than 10 mm.
6.6.10. Checked every connection of hydraulic jack before start to
jacking up.
6.6.11. Only operator of jack is allowed to control the control valve.
6.6.12. Each hydraulic jack will be lifted until 40 cm on the single
move and it will moved synchronized
6.6.13. Every single hydraulic jack shall be monitored by one person;
this person will place the mild steel profile when the hydraulic
jacks reach the maximum height.
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6.6.14. Jacking the tank to the height 2,000 mm, then starts erect the
next shell plates.(Figure 4)

(Figure 4)
6.6.15. When all shell plates are finished than start the process of fit up
and welding until finish.
6.6.16. Before jacking up the next shell again, the inspection shall be
carried out, such as peaking, banding, plumbness, roundness
and radiography
6.6.17. Support bracket shall be removed from the previous shell plate
and installed again on the new shell plates for continuing
erection the next shell plate.(Figure 5 and Figure 6)

(Figure 5)
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(Figure 6)

6.6.18. Continue the process similarly, until the last shell plate erected
(shell 1)
6.6.19. After all last shell plates (Shell 1) were welded and inspected,
than the support beam on the annular plate shall be removed.
6.6.20. With the hydraulic jack put the last shell plate (shell 1) seated
on the annular plate.
6.6.21. Fit up the corner joint of shell plate and annular plate.
6.6.22. Before start welding on the corner joint, check the plumbness
and roundness of the tank.
6.6.23. Welding the corner joint from the inside of joint. Used the right
angle vacuum box to inspect welding, check if there any leak
on the welding.

6.6.24. All the temporary support, jack equipments, jigs and tools shall
be removed.
6.6.25. When inside of the tank is cleaned, the process of vacuum on
the bottom plate shall be proceed.
6.6.26. All the tank accessories and nozzle shall be installed once the
welding on the corner joint completed.
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6.6.27. Installation of tank accessories and nozzle shall be accordance

to approved drawing.
6.6.28. All the reinforcement plate for nozzle shall be inspected by
pneumatic through the tell tale hole.
6.6.29. All the inspection for the tank such as visual, plumbness,
roundness, peaking, banding, pneumatic and radiography shall
be done before staring for water filling or hydrostatic test.
6.6.30. Check all nozzles and manholes are bolted tightly than the
water can be pump into the tank.

7. Inspection.

7.1. The process of inspection shall be accordance to approved ITP

(Inspection Test Plan).
7.2. The inspection consists of:
Peaking
Banding
Plumbness
Roundness
Vacuum
Pneumatic
Radiography
Hydrostatic

7.3. Peaking

7.3.1. Peaking inspection is measuring the joint on the shell plate,

especially on the vertical joint of the shell plate.
7.3.2. The tool for peaking inspection is wooden board, where on side
of the board have a curve that follow the radius of the tank that
shall be inspected.
7.3.3. The minimum board for peaking inspection is 900 mm.
7.3.4. Placed the wooden board on the shell surface with horizontal
position.
7.3.5. Visually seeing the gap between the wooden board and the
vertical joint shell plate.
7.3.6. Measured the gap with small iron ruler.
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7.3.7. The maximum tolerance gap for peaking inspection is 13 mm.

7.3.8. If the gap exceeds 13 mm, than the vertical joint shall be
repaired.
7.3.9. After the repaired, the gap shall be measured again until the gap
not exceeds 13 mm.
7.3.10. Applied this peaking inspection to all shell plate vertical joint.
7.3.11. Quality Control shall be recorded the result into Peaking
Inspection report.

7.4. Banding

7.4.1. Banding inspection is measuring the joint on the shell plate,

especially on the horizontal joint of the shell plate.
7.4.2. The tool for peaking inspection is wooden board, where both
side of the board have to be straight.
7.4.3. The minimum board for peaking inspection is 900 mm.
7.4.4. Placed the wooden board on the shell surface with vertical
position.
7.4.5. Visually seeing the gap between the wooden board and the
horizontal joint shell plate.
7.4.6. Measured the gap with small iron ruler.
7.4.7. The maximum tolerance gap for peaking inspection is 13 mm.
7.4.8. If the gap exceeds 13 mm, than the horizontal joint shall be
repaired.
7.4.9. After the repaired, the gap shall be measured again until the gap
not exceeds 13 mm.
7.4.10. Applied this banding inspection to all shell plate horizontal
joint.
7.4.11. Quality Control shall be recorded the result into Banding
Inspection report.

7.5. Plumbness

7.5.1. Plumbness inspection is to measure the slope of the tank.

7.5.2. Plumbness inspection shall be conducted on the first erected
shell plate.
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7.5.3. The first shell plate shall be checked the plumbness because it
will determine the slope of the nest shell plate.
7.5.4. Plumbness inspection shall be conducted on several point of
degree such as 0, 45, 90, 135, 180, 225, 270 and 315.
7.5.5. The equipment for plumbness is the elbow ruler or
perpendicular ruler, which the other end of ruler will tied with
the string. And at the other end of string tied to the weight.
7.5.6. Placed the elbow ruler tied with the string on the top of the
shell plate with a distance 100 mm from the surface.
7.5.7. Measured the length relatively at the bottom of the shell shall
not exceed 1/200 of the total tank height.

Description 1/200 x total tank height (mm)

Condensate Tank 50
Fire Water Tank 55

7.5.8. Plumbness inspection shall be conducted on every shell plate

erected.
7.5.9. Quality Control shall be recorded the result into Plumbness
inspection report.
7.6. Roundness.

7.6.1. Roundness inspection is to measure the roundness of the tank.

7.6.2. Roundness inspection shall be conducted on the first erected
shell plate.
7.6.3. The first shell plate shall be checked the roundness because it
will determine the roundness of the nest shell plate.
7.6.4. Roundness inspection shall be conducted on several point of
degree such as 0, 45, 90, 135, 180, 225, 270 and 315.
7.6.5. The equipment for roundness inspection is measuring tape.
7.6.6. Pull the measuring tape from the center of the tank to shell
plate surface with the height 300 mm from the bottom plate.
7.6.7. Measured the tank radius and continue the process at other
degree.
7.6.8. The tolerance radius of roundness as follow:
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Tank Diameter (m) Radius Tolerance (mm)

< 12 13
From 12 to < 45 19
From 45 to < 75 25
75 32

7.6.9. The tank diameter for Condensate tank is 36.88 m and fire
water tank is 13.71 m
7.6.10. The tolerance for both condensate and fire water tank is 19 mm.
7.6.11. Quality Control shall be recorded the result into Roundness
Inspection report.

7.7. Vacuum.

7.7.1. Vacuum inspection is checking a leak on the lap welding joint

on the bottom plate
7.7.2. With the right angle corner vacuum box, can be conducted the
inspection for corner joint of shell plate and annular plate.
7.7.3. Before the lap welding joint being vacuum box test the welding
area have to be visually check and have to be clean from mud,
soil, dust and other thing that not expected.
7.7.4. Vacuum box is complete with valve and vacuum gauge that
have been calibrated, compressor, and rubber hose, clam, and
gasket seals.
7.7.5. Bottom welding have to be test using vacuum with pressure 20
kPa up to 35 kPa.
7.7.6. Approximately 750 mm of welding that will be test shall be
applied the soap solution.
7.7.7. Vacuum box test shall have at least 50 mm overlap of
previously viewed surface on each application.
7.7.8. The bottom plate surface temperature limits shall be between
4C and 52C.
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7.7.9. Minimum light intensity of 1000 lux at the point of

examination is required during the application of the
examination and evaluation for leaks.
7.7.10. The vacuum shall be maintained for greater or at least 10
seconds time required viewing the area under test for leaks.
7.7.11. The presence of leaks indicated by continuous formation or
growth of bubble or foam, produced by air passing through is
unacceptable.
7.7.12. The leaks shall be repaired and retested.
7.7.13. Quality Control shall be recorded the results into vacuum
inspection report.

7.8. Pneumatic.

7.8.1. Pneumatic test is a process by applying air pressure into

reinforcing plate to check if there are any leaks on the
reinforcing weld.
7.8.2. After all reinforcing plate for nozzles installed but before the
tank is filled with water; the reinforcing plate shall be tested by
applying air pressure up to 100 kPa.
7.8.3. Applied the welding on reinforcing plate with soup solution,
than applied the air pressure through telltale hole
7.8.4. Both inside and outside of reinforcing plate shall be tested.
7.8.5. If there are leaks found, than the welding on the reinforcing
plate shall be repaired and retested.
7.8.6. Quality Control shall be recorded the results into Pneumatic test
report.

7.9. Radiography.
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7.9.1. Radiography inspection is required for shell butt welds and

annular plate butt welds.
7.9.2. Radiography inspection is not required for roof plate welds,
bottom plate welds, welds joining the top angle to either the
roof or shell, welds joining the shell to the annular plate and
welds in nozzle and manhole.
7.9.3. Quality Control shall provide the Radiography map for
approval.
7.9.4. The quantities of film and spots of radiography shall be applied
in accordance to the approved radiography map.
7.9.5. Each radiography shall clearly show a minimum of 150 mm of
weld length.
7.9.6. The process of radiography shall be conducted by qualified
NDT Company.
7.9.7. To interpret the result of radiography shall be conducted by
inspector level 2 of the NDT Company.
7.9.8. All the results of radiography inspection shall be collected by
Quality Control and compiled into Manufacture Data Report.
7.10. Hydrostatic.

7.10.1. Hydrostatic test conducted for leaks, slope and to determine if

construction can withstand tank load weight during operation
without failure.
7.10.2. Hydrostatics test also to check the strength of the tank
foundation to decrease of the tank foundation elevation.
7.10.3. Equipments for hydrostatic test:
Distribution water pump
Pipe or hose
Temporary gasket for manhole and nozzles.
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Blind flange
Valve
Transparent hose
Survey equipment like theodolite.
7.10.4. Before filling the water, the following shall be checked:
7.10.4.1. All welding and all other inspection shall be
finished.
7.10.4.2. The level on the tank shall be recorded by
measured the surrounding elevation of tank
diameter.
7.10.4.3. All the temporary tools or jigs shall be removed
and cleaned
7.10.4.4. All nozzles shall bolt tightly with the blind flange.
7.10.4.5. Installed pipe or hose to the tank and connected to
the distribution water pump.
7.10.4.6. Installed the transparent hose along the stairway for
easy identifying the level of water been reach.
7.10.5. The water shall be filled into certain level and shall stop before
continue to the next level.
7.10.6. The level of water filling is 25%, 50%, 75% and 100% of the
tank height.
7.10.7. For the level of 25%, 50%, and 75% that water shall stop and
check for leaks, and hold for 12 to 24 hours.
7.10.8. After holding the water for 12 to 24 hours the level elevation of
foundation shall checked.
7.10.9. For final water filling to 100%, the water shall be hold for at
least 24 to 48 hours.
7.10.10. Quality Control shall be recorded the results into Hydrostatic
Inspection report.
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7.11. Pre-commissioning.

7.11.1. Pre commissioning is to check all accessories are installed to its

place and accordance to approved drawing.
7.11.2. Check every instrument and valve is connected tightly
7.11.3. Check all the surface area if there are any defect before the
commissioning.