Rangkuman QC Konstruksi-1
Rangkuman QC Konstruksi-1
SURVEYING INSPECTION
Pengukuran untuk penentuan posisi relative suatu titik yang berada diatas, dan dibawah permukaan bumi.
Construction Survey
Sifat-sifat Concrete :
Grout : material epoxy atau semen yang dipakai untuk memberikan suatu support pondasi
yang seragam dan hubungan transfer beban untuk pemasangan static equipment & rotating
equipment.
1. Persiapan Pondasi :
a. bebas minyak/oil/lemak
b. bebas sisa concrete dan permukaan harus
dikasarkan
c. permukaan hrs basah/kering (sesuai type grout)
5. Penyelesaian (Finishing)
a. Melepas form work dan merapikan pinggirannya
6. Perawatan (Curing)
a. Memberikan curing compound sesuai dengan manufacturer recommendation
b. Tidak diberikan beban sampai mencapai 75% kekuatan (sampai 7 hari)
c. Dry pack grouting, curing dilakukan dengan
* Kolam air/ semburan air yang kontinyu
* Pemberian mat/fabric yang terus basah
* Pemberian pasir yang terus basah
Welding (Pengelasan) : penyambungan logam secara metalurgi dengan menggunakan panas & tekanan,
dengan atau tanpa filler metal yang mempunyai titik cair yang hampir sama
Kualifikasi Welding bertujuan : menentukan apakah lasan yang dipropose untuk konstruksi dapat
menyediakan sifat-sifat yang disyaratkan untuk applikasi yang diinginkan
Aktifitas pengelasan dikonstruksi tidak boleh dimulai bila welding belum kualifikasi
Salah satu Code Welding : ASME Section IX “Welding & Brazing Qualification”
Dalam ASME IX, Welding Procedure lebih dikenal dengan nama Welding Procedure Specification (WPS)
WPS berisi kondisi detail untuk applikasi spesifik, untuk menjamin pengulangannya oleh welder atau
welding operator.
WPS harus dibuktikan oleh Procedure Qualification Record (PQR) yang berisi data-data pengelasan test
coupon dan hasil aktual dari spesimen yang ditest.
Variabel-variabel yang tercantum dalam WPS :
1. Joint Design
2. Base Metal
3. Filler Metal
4. Posisi pengelasan
5. Preheat
6. Postweld Heat Treatment
7. Electrical Characteristic
8. Technique
1. Welding Process,
2. Backing (metal, weld metal, flux)
3. Base Metal
4. Diameter
5. Filler Metal (Spec, Thickness Deposit)
6. Posisi
7. Arah Pengelasan
8. Gas
9. Karakteristik Listrik
5. WELDING INSPECTION
Preheating
Dilakukan dengan menaikkan temperatur dari base metal diatas temperatur sekitarnya sebelum pengelasan
dilakukan, yang dapat dilakukan untuk seluruh benda yang akan dilas atau hanya pada bagian yang akan
dilas (local preheat)
Tujuan Preheat :
a. Pencegahan terjadinya retak dingin (cold crack)
b. Mengurangi kekerasan pada daerah HAZ
c. Mengurangi tegangan sisa (residual stress)
d. Mengurangi distorsi
DESTRUCTIVE TEST (DT) : test merusak yang dilakukan terhadap material untuk mengetahui
karakteristik specifik material tersebut
Jenis-jenis DT :
Tensile Test
Menentukan karakteristik material dalam hal :
Ultimate Tensile Strength
Yield Strength
Ductility
Percent Elongation
NON DESTRUCTIVE TEST : test tidak merusak yang dilakukan terhadap material sebagai bahan
evaluasi terhadap karakteristik kualitas material
Jenis-jenis NDT (yang umum dipakai) :
a. Penetrant Test
Mengetahui discontinuity permukaan suatu material (crack, pori, porosity etc)
Prinsip kerja : penetrant cair diberikan pada permukaan, meresap kedalam bukaan permukaan
(kapilaritas), dibersihkan terhadap kelebihan penetran dan kemudian
suatu bubuk kering (developer) diberikan agar dapat menarik penetrant dari bukaan permukaan (surface
opening).
Penetrant biasanya berwarna merah, sehingga indikasi terlihat jelas terhadap background putih
bubuk kering (developer)
PAINTING
Proteksi material terhadap serangan korosi dan estetika
Jenis-jenis inspeksi painting yang biasa dilakukan:
a. Inspeksi Profile Surface; Memeriksa kekasaran permukaan setelah di lakukan proses Sand Blasting
dengan Alat Keane Tator Surface Profile Comparator
b. Inspeksi Dry Film Thickness; Memeriksa ketebalan lapisan cat pada material setelah kering dgn
Alat Elcometer (Thickness Gauge)
c. Inspeksi Pinhole (Lubang Halus) atau Holiday test dgn alat Holiday Detector
d. Inspeksi Daya Lekat (Adhession) dgn alat Cross Cut Test (Tape), Elcometer Adhession Test
ALIGNMENT
Proses mengurangi ketidaklurusan (misalignment) dari 2 (dua) shaft yang dihubungkan dengan
kopling (coupling) sehingga pusat putaran dari tiap shaft sepraktis mungkin linier selama pengoperasian
normal
Jenis-jenis Alignment :
a. Axial (Linear) Alignment : membuat dua shaft berada pada satu garis sumbu linier
b. Angular (Vertical) Alignment :membuat muka dua coupling berada pada satu garis sejajar
Metoda Alignment :
a. Reverse Rim (Dial) Alignment
b. Rim & Face Alignment
GENERAL TESTING
Diantaranya Pressure/Leak Test, untuk mendeteksi adanya kebocoran pada system setelah
dilakukan tahapan-tahapan inspeksi dan test. Jenis-jenis Pressure/Leak Test :
VI.OTHER
1. Indonesia
a. MIGAS Regulation : regulation pertaining to Oil & Gas sector, eg :
MIGAS Regulation No 84.K/38/DJM/1998 : Pedoman dan Tata Cara Pemeriksaan Keselamatan
Kerja atas Instalasi, Peralatan dan Teknik yang Dipergunakan Dalam Usaha Pertambangan Minyak dan
Gas Bumi dan Pengusahaan Sumber Daya Panas Bumi
3 AWS
2.1. AWS D1.1 : Structural Welding Code Rule for structural welding construction
2.2. AWS D1.5 : Bridge Welding Code Rule for welding fabrication requirement in highway bridges
4 AWWA
4.1. AWWA M17 : Installation, Field Test Rules for installation, field testing and maintenance of fire hydrant
& Maintenance of Fire'
Hydrant
Examples :
• DIN 2559 PT1 : Edge Preparation for Welding; Direction Regarding Edge Forms;Fusion Welding of
Butt Joint in Steel Tubes
• DIN 2617 : Steel Butt Welding Pipe Fitting
• DIN 8563 : Quality Assurance in Welding Operation
• DIN 8560 : Qualification Testing of Welder for Welding Steel
• DIN 8564 PT1 : Welding of Pipeline, Steel Pipelines, Manufacturing, Testing of Weld
• DIN 8570 PT1 : General Tolerances for Welded Structure, Linear and Angular Dimension
• Etc
a. GB 5310 : Seamless Steel Tubes and Pipes for High Pressure Boiler
b. GB DL5007 : The Specification of Erection and Acceptance for Power Plant Construction
c. GB T8162 : Structure Pipe
d. GB 150: Steel Pressure Vessel
e. GB 151 : Tubular Heat Exchanger
f. Etc
No Standard/Code No Standard/Code
1 ISO International Organisation for Standardization 26 AGA American Gas Association
2 ASTM American Society for Testinf and Material 27 ARI Air Conditioning and Refrigeration Institute
3 ANSI American National Standard Institute 28 ASHRAE American Society of Heating Refrigerating
4 CSA Canadian Standard and Air Conditioning
5 SAE Society of Automotive Engineer 29 ASSE The American Society of Sanitary Engineers
6 NBR Brazilian Standard 30 ASCE American Society of Civil Engineers
7 NOM Mexican Burueau of Norms 31 ASNT American Society for Non Destructive Test
8 COVENIN Venezuelian Commision on Industrial Standard 32 AISI American Iron and Steel Institute
9 IRAM Argentinian Standard Institute 33 ANS American Nuclear Society
10 NAG Argentinian Standards 34 BOCA The Building Official Conference of America
11 EN European Committee for Standardisation 35 EJMA Expansion Joint Manufacturer Association
12 AFNOR French Association for Standardization 36 FCI The Fluid Control Instritute
13 UNI Italian National Standard Institute 37 FSA The Fluid Sealing Association
14 UNE Spanish Standard 38 HEI The Heat Exchanger Institute
15 SIS Swedish Standard 39 HI The Hydraulic Institute
16 SFS Finnish Standard 40 IEEE The Institute of Electrical & Electronic Eng
17 ISIRI Institute of Standards and Industrial Research 41 ISA The Instrument Society of America
of Iran 42 NFPA The National Fire Protection Association
18 GOST Russian Standard 43 MSS Manufacturer Standardisation Society
19 TS Turkish Standard 44 PFI Pipe Fabrication Institute
20 CSN Czech Standard Institute 45 SSPC Steel Structure Painting Council
21 MSZ Hungarian Standard 46 TEMA Tubular Exchanger Manufacturer Ass
22 KS Korean Standard 47 PPI Plastic Pipe Institute
23 CNS Taiwan National Standard 48 ACI American Concrete Institute
24 IS Indian Standard 49 ASM American Society of Metal
25 AS Australian Standard 50 ETC
SPECIFICATION
TECH. SPEC. IS SPECIFICATION HOW TO EXECUTE ALL TECHNICAL WORKING AS PER CONTRACT.
Eq; Spec. Material to be used, Receiving, Handling and Storaging , Earthling, Pilling, Concreting, Grouting,
Tightening, Welding, Forming, Bending, Rolling, Preheat, PWHT, Painting, Insulation, Cleaning,
Inspection, Testing and Commissioning.
TECHNICAL SPECIFICATION IS VERY2 IMPORTANCE TO PRICING ISTIMATION, DOING THE WORK
UNTIL PROJECT FINISHED, SO ALL ENGINEERS OR SPV SHALL BE FAMILIAR WITH THIS
SPECIFICATION
CLASIFICATION PROJECT DOCUMENT BASED ON THE LEVEL TO BE FOLLOWED:
1. Vendor / Manufacturer Manual
2. Specification (Client or Owner)
3. Standard and Code
4. Commence
QA QC INSPECTOR RESPONSIBILITY
RESPONSIBILITY
To study and understand Client Technical Specification (Drawing, Procedure, Specification,
Standard/Code)
To perform Inspection and Test according to Project Quality Plan, Client Technical Specification,
applicable Standard/Code & Procedure/Work Instruction
To conduct Welder Performance Qualification Test in accordance with Standard/Code and control
the Welder Performance during production
To control all variables of WPS before, during and after welding process to ensure that the result of
welded joint according with acceptance criteria of Standard/Code
To conduct the non-destructive Examination of Welded Joint as required by the Client Specification
To conduct the Pre and Post Weld Heat Treatment associated with Welding Process
To control Measuring and Testing Equipment (MTE) Calibration for those are using at field
To control the status of each items to be inspected and whatever in line with testing process to
ensure that each stage of process in accordance with Client Specification
To make report for each item to be inspected and tested and documented in properly way
AUTHORITY
To stop work if the quality of work is not accordance with Project Quality Plan, Contract
Specification and applicable procedure or drawing and immediately report to QC Engineer and Field
Engineer
To sign off the Quality Inspection Records within the scope of work
To issue the Non Conformance Report to the activity which not conform to the Client Technical
Specification and Standard/Code
QA/QC Planning
– First start, the QC Engineer shall collect and check the below project documents (as Input) to provide
next job;
• Project Schedule
• Project Scope of Work
• Technical Specification & Requirement
• Supporting Documents
– Standards and Codes
– Drawings
– Bill of Quantity (BQ) or Material take off (MTO)
– Procedures (if any)
– QC Engineer next jobs are;
• Prepare Project Quality Plan (PQP)
• Prepare WPS/PQR if required
• Prepare Inspection & Test Plan (ITP)
• Prepare Quality Control procedure if required
• Prepare QC structure organization c/w job description
• Man Power(QC) loading schedule
• Prepare Request Order for QC Tools & Manpower
• Make a list the below documents;
– List of all project procedures c/w numbering system
– List of all Technical Specifications
– List of QC Tools
– List of Standards and Codes will be used
– List of WPS/PQR
– List of Piping Data Class c/w NDT, PWHT, TESTING requirements
– List of Drawing
• Prepare filing and documentation system