PROSES INSPEKSI & TESTING BALL

VALVE

PT. TEKNOLOGI REKAYASA KATUP

JL. RAYA SERANG KM.39
DESA PARIGI, KEC. CIKANDE
KAB. SERANG, PROVINSI BANTEN
 MATERI PROSES INSPEKSI

1. Alur Proses Inspeksi

2. Kualifikasi Personel
3. Pengendalian Alat Ukur
4. Incoming Inspection
5. Inspection After Machining
6. Inspection After Assembling
7. Pressure Testing
8. Inspeksi Blasting & Painting
9. Inspeksi Marking
ALUR PROSES
ENGINEERING
CUSTOMER MARKETING
(Design & Calculation)

INCOMING NCR
PROCUREMENT
MATERIAL

NC ACC
INSPEKSI INSPEKSI
SUPPLIER WAREHOUSE MACHINING QC
QC

ACC

NCR ASSEMBLY

BLASTING ACC ACC

PRESSURE INSPEKSI
& TEST QC
PAINTING

INSPEKSI
QC
NCR

NCR
ACC INSPEKSI
PACKAGING DELIVERY
QC
 KUALIFIKASI PERSONNEL

Persyaratan: API 6D 24th Edition, Klausal 8.3 Qualification of Personnel

1. NDE Personnel, dikualifikasi berdasarkan persyaratan yang ditentukan

berdasarkan ASNT SNT-TC-1A atau ISO 9712 (Klausal 8.3.1)

2. Visual Inspector, lulus annual vision examination berdasarkan ASNT SNT-

TC-1A atau ISO 9712 (Klausal 8.3.2)

3. Welding Inspector, Qualified & certified (Klausal 8.3.4):

a. AWS QC1 or equivalent certified welding inspector, or
b. AWS QC1 or equivalent senior certified welding inspector, or
c. AWS QC1 or equivalent certified assosiated welding inspector, or
d. welding inspector disertifikasi oleh manufakturer.

4. Personel yang lainnya, dikualifikasi berdasarkan persyaratan

terdokumentasi dari manufakturer. (Klausal 8.3.3)
 PENGENDALIAN ALAT UKUR

Persyaratan:

API 6D 24th Edition, Klausal 8.2 Measuring & Test Equipment

8.2.1. Umum.
Alat ukur yang digunakan untuk inspeksi, pengujian, atau pengukuran harus
diidentifikasi, dikendalikan, dikalibrasi dengan interval berdasarkan instruksi kerja
yang berlaku di Manufaktur.
Maksimum periode kalibrasi tidak lebih dari 1 tahun.
8.2.2. Alat Ukur- Dimensi
Alat ukur-dimensi harus dikendalikan dan dikalibrasi berdasarkan dengan metode
yang ditentukan dalam prosedur.
8.2.3. Alat Ukur- Tekanan
8.2.3.1. Alat ukur tekanan harus memiliki akurasi sekurang-kurangnya ± 2% dari full
scale. Dan pembacaannya harus pada range 20 % sampai 80 %.
8.2.3.2. Dikalibrasi minimal 3 titik pembacaan (diluar nol dan full Scale)
8.2.3.3 Interval Kalibrasi, maksimum 3 bulan.
Contoh Sertifikat Kalibrasi
Contoh Sertifikat Kalibrasi ALAT UKUR PT. TRK

Alat Ukur yang digunakan:

1. Caliper
2. Micrometer
3. Hardness Testing
4. Positive Material Identification
5. Ultrasonic Flow Detector
6. Pull Pain-Off Test
7. High gauge
8. CMM (
Coordinate-measuring machine)
9. Infrared Thermometer
10. Dial Depth Gage
11. Thermo hygrometer
12. Coating thickness
13. UT Thickness Meter
14. Roughness Tester
15. Duro meter
16. Torque Wrench
17. Pressure gauge
 REKANAN KALIBRASI PT. TRK

Rekanan Laboratorium Kalibrasi:

1. WIKA Instrumentation Pte Ltd
2. PT. Pratita Prama Nugraha
3. Bruker AXS Hanheld INC
4. PT. Caltesys Indonesia
5. Hexagon Metrology Service
6. Hi-Force Hydrolic
7. PT. Unilab Perdana
8. PT. GMF Aeroasia
9. PT. Arfindo Bersinar
10.Balai Besar Kimia dan Kemasan
11. PT. Mandiri Transforma Global
 INCOMING NSPECTION

DIMENSIONAL CHECK
Persyaratan:
Engineering Drawing
 INCOMING NSPECTION

MANUAL ULTRASONIC EXAMINATION

Persyaratan:

API 6D 24th Edition, Annex G.

Klausal: G.10, G.14, ASME B16.34,
Appendix IV

G.10. UT of forging & Plate on 100% of Surface Area.

Examination & Acceptance harus berdasarkan dengan
ASME B16.34 Appendix IV
 INCOMING NSPECTION

Persyaratan: HARDNESS TEST

API 6D 24th Edition,

Klausal 7.4
 INCOMING NSPECTION

PMI TEST

* POSITIVE MATERIAL IDENTIFICATION (PMI)

PMI testing dilakukan oleh operator
QC untuk mengetahui kandungan
komposisi material.

Proses PMI pada

Raw Material Body
Verifikasi Alat
 INCOMING NSPECTION

OTHER PART
FINISH
O-Ring Bleder Fitting
Bolt & Nut

Sliding Bearing
 INSPECTION AFTER MACHINING

* CEK DIMENSI
Cek dimensi dilakukan oleh
operator QC menggunakan form
Lembar Pengecekan Proses
Permesinan

Proses pengecekan
oleh operator QC
 NSPECTION AFTER MACHINING

LIQUID PENETRAN
EXAMINATION

Persyaratan:

API 6D 24th Edition, Annex G.

Klausal: G.12, G.16, G.19, G.21, G24, G25,
ASME BPVC, Section V Article 6, ASME BPVC
Section VIII Division I Appendix 8.

ASME BPVC Section VIII Division I

Appendix 8.
Semua permukaan harus bebas dari:
a. Relevant liniear Indication (1.5mm)
b. Relevant rounded indication lebih besar
dari 5mm
c. Empat atau lebih relevant rounded
indication in a line sparated by 1.5 mm or
less, edge to edge
 INSPECTION AFTER MACHINING

* NON DESTRUCTIVE TESTING

- Magnetic Test (MT)
Persyaratan:

API 6D 24th Edition, Annex G.

Klausal: G.11, G.15, G.18, G.20, G22, G26, ASME
BPVC, Section V Article 7, ASME BPVC Section
VIII Division I Appendix 6.

ASME BPVC Section VIII Division I

Appendix 6.
Semua permukaan harus bebas dari:
a. Relevant liniear Indication (1.5mm)
b. Relevant rounded indication lebih besar
dari 5mm
c. Empat atau lebih relevant rounded
indication in a line sparated by 1.5 mm or
less, edge to edge
 INSPECTION AFTER MACHINING

* CEK DIMENSI
Selain cek manual, quality dapat melakukan
pengecekan dengan menggunakan mesin Coordinate
Measuring Machine ( CMM )

HEXAGON GLOBAL ADVANTAGE

20.33.15
 INSPECTION AFTER ASSEMBLY

* Anti Static Test Report (API 6D 24th Edition, Klausal. 5.23, H.5, max. 10 )

Dilakukan dengan 2 tahap dan masing-masing tahap 3 proses pengetesan

dalam titik yang berbeda.

- Ball to Body

- Stem to Body

Contoh Form Antistatic

Report
 PRESSURE TESTING

Persyaratan:
API 6D 24th Edition
1. Media fluida harus air bersih dan harus mengandung corrosion
inhibitor
2. Temperatur media fluida tidak boleh lebih dari 38 ºC.
3. Untuk austenitic dan duplex stainless steel, cloride contents tidak boleh
lebih dari 30 µg/g (30 ppm by mass)
 FASILITAS MESIN PRESSURE TESTING

KODE MODEL DAN TAHUN

NO SPECIFIKASI MESIN / ALAT
MESIN/ALAT SERIAL NUMBER PEMBUATAN
1 HM 1 DORY YFJ-H600 Maret 2016 valve size range 100 ~ 600 , Nominal Diameter 4"~ 24 "
    SN: 95913   Max Clamping force: 900 ton.
        Power Supply : 380V / 50Hz . Motor Power 7,5/4,0 KW
        Net Weight: 21000 kg
2 HM 2 DORY YFJ-H300 Januari 2016 valve size range 65 ~ 300 , Nominal Diameter 2 1/2" ~ 12 "
    SN: 95912   Max Clamping force: 185 ton.
        Power Supply : 380V / 50Hz . Motor Power 3,0/3,0 KW
        Net Weight: 4500 kg
3 HM 3 DORY YFJ-H150 Januari 2016 valve size range 15 ~ 150 , Nominal Diameter 1/2" ~ 6 "
    SN: 95911   Max Clamping force: 35,5 ton.
        Power Supply : 380V / 50Hz . Motor Power 2,2/3,0 KW
        Net Weight: 1500 kg

PRESSURE TESTING NOTES:

Pc = pressure rating class designation (ASME B16.34)
Class: 150 300 600 900 1500 2500
Pc [bar]: 19.6 51.1 102.1 153.2 255.3 425.5
Pc [Psi]: 284.2 740.95 1480.5 2221.4 3701.9 6169.8
 PRESSURE TESTING

Ada beberapa tahap proses pengetesan tekanan pada ball valve, antara lain :
1. Hydrostatic Shell Test (API 6D 24th Edition, Klausal 9.3)
Fluid : Water
Pt = 1.5 x Pc
Durasi pengetesan : NPS ≤ 4“ = 2 menit
6“ ≤ NPS ≤ 10“ = 5 menit
12“ ≤ NPS ≤ 18“ = 15 menit
NPS ≥ 20“ = 30 menit
Testing temperature: max. 38 ºC
Acceptance Criteria: No Visible leakage

Shell Test Ball Valve 6”-150 LB, Pt = 428 Psi, duration: 5 Menit, Testing Temp: 30 ºC
 PRESSURE TESTING

2. Torque Functional (API 6D 24th Edition, Klausal. H.6)

- Fluid : Water
Pt = 0
Durasi pengetesan : Min 2 Cycles

- Fluid : Water
0 ≤ Pt ≤ Pc gradually after 10 bar
Durasi pengetesan : Min 3 Cycles

- Fluid : Water
0 ≤ Pt ≤ Pc gradually after 10 bar
Durasi pengetesan : Min 2 Cycles

Torque FunctionalTest Ball Valve 6”-150 LB

 PRESSURE TESTING

3. Hydrostatic High Pressure Seat Test (API 6D 24th Edition, Klausal. 9.4)
Fluid : Water
Pt = 1.1 x Pc
Durasi pengetesan : NPS ≤ 4“ = 2 menit
6“ ≤ NPS ≤ 18“ = 5 menit
NPS ≥ 20“ = 10 menit
Acceptance Criteria: No Visible leakage for soft-seated valves, (API 6D 24th Edition,
Klausal 9.4.3 & ISO 5208 Rate A)
For metal-seated valves (drops/s):
0.016 X DN (ISO 5208 Rate D)

Seat Test Ball Valve 6”-150 LB, Pt : 314 Psi, duration : 5 Menit, Testing temp: 30 ºC
 PRESSURE TESTING

4. Low Pressure Gas Seat Test (API 6D 24th Edition, Klausal H.3)
Fluid : Air or Nitrogen
Pt = 80 Psi to 100 Psi
Durasi pengetesan : NPS ≤ 4“ = 2 menit
6“ ≤ NPS ≤ 18“ = 5 menit
NPS ≥ 20“ = 10 menit

Acceptance Criteria: No Visible leakage for soft-seated valves, (API 6D 24 th Edition,

Klausal 9.4.3 & ISO 5208 Rate A)
For metal-seated valves (drops/s): (0.4584 X DN) (ISO 5208 Rate D)

Low Pressure Gas Test Ball Valve 6”-150 LB, Pt: 80 Psi, duration : 5 menit, Testing Temp: 30 ºC
 PRESSURE TESTING

5. DPE High Pressure Seat Test ( API 6D 24th Edition, Klausal 9.4.4.3)
Fluid : Water
Pt = 1.1 x Pc
Durasi pengetesan : NPS ≤ 4“ = 2 menit
6“ ≤ NPS ≤ 18“ = 5 menit
NPS ≥ 20“ = 10 menit

DPE High Pressure Seat Test Ball Valve 6”-150 LB, Pt : 314 Psi, duration : 5 Menit, Testing temp: 30 ºC
 PRESSURE TESTING

6. DPE Low Pressure Gas Seat Test ( API 6D 24th Edition, Klausal H.3)
Fluid : Air or Nitrogen
Pt = 80 Psi to 100 Psi
Durasi pengetesan : NPS ≤ 4“ = 2 menit
6“ ≤ NPS ≤ 18“ = 5 menit
NPS ≥ 20“ = 10 menit

DPE Low Pressure Gas Seat Test Ball Valve 6”-150 LB, Pt: 80 Psi, duration : 5 menit, Testing Temp: 30 ºC
 PRESSURE TESTING

7. High Pressure Gas Seat Test (API 6D 24th Edition, Klausal H.4)
Fluid : (99 % N2, 1% He)
Pt = 1.1 x Pc
Durasi pengetesan : NPS ≤ 4“ = 2 menit
6“ ≤ NPS ≤ 18“ = 5 menit
NPS ≥ 20“ = 10 menit
Acceptance Criteria: No Visible leakage for soft-seated valves, (API 6D 24th Edition,
Klausal 9.4.3 & ISO 5208 Rate A)
For metal-seated valves (drops/s):
Max. 2X(0.4584 X DN) (ISO 5208 Rate D)

Seat Test Ball Valve 6”-150 LB, Pt : 314 Psi, duration : 5 Menit, Testing temp: 30 ºC
 PRESSURE TESTING

8. Cavity Relief Test/ SPE Test (API 6D 24th Edition, Klausal 9.4.4.4)
Ball valve dengan internal Relieving Seat (SPE)

Fluid : Water
Pt = 0 and Pt = Pc
P sampai dengan 1.33% PC
Durasi pengetesan : -
 PERLAKUAN SETELAH PRESSURE TESTING

Setelah Pengujian
Pressure testing
dilakukan, valve harus
dikeringkan dari fluida
pengujian, dibersihkan,
dan dilubrikasi
 BLASTING INSPECTION

Proses Blasting untuk menghilangkan karat ataupun coating yang menempel

pada material, blasting menggunakan material: Pasir besi atau mineral
abbrasive seperti aluminium oxide dengan kehalusan sebagaimana ISO-8501-
1 Sa 2.5 sampai Sa3).

Pasir Besi
Proses blast
 PROSES PAINTING

Berikut ialah spesifikasi manufaktur standar painting TRK dan prosesnya.

Proses Painting
Persyaratan Coating/Painting:

API 6D 24th Edition: Klausal 10, Annex L

 INSPEKSI PAINTING

Setelah proses painting, tebal cat di ukur dengan menggunakan alat ukur
“coating thickness” untuk memastikan hasil painting sudah sesuai standard
pabrik atau permintaan customer.

Proses Pengecekan tebal cat

 INSPEKSI PAINTING

Proses Pull-Off Paint Testing ( ASTM D4541)

Persyaratan minimum kekuatan adhesion adalah 6 MPa untuk hydraulic tester dan
4 MPa dengan mechanic tester.

Paint Pull Test Tools Result after test on filter modul as

Pull off test at 1st Dolly
Dolly 1st.

Result after test on filter Result after test on filter modul as

Pull off test at 2nd Dolly Pull off test at 3rd Dolly Dolly 3rd
modul as Dolly 2nd
INSPEKSI MARKING

Name Plate

Seat Plate
PERSYARATAN DOKUMENTASI