This document outlines the procedures for conducting a mockup test for ultrasonic testing (UT) personnel recruitment at PT.Spektra Megah Semesta. It describes the general steps of the mockup test which include an initial screening of personnel qualifications, a demonstration of equipment calibration, performing UT on specimens, and reporting results. The main purpose is to ensure UT personnel can accurately perform inspections to minimize leaks at PHE ONWJ's oil and gas facilities. The test also aims to evaluate personnel competency levels to match them with appropriate job roles.
This document outlines the procedures for conducting a mockup test for ultrasonic testing (UT) personnel recruitment at PT.Spektra Megah Semesta. It describes the general steps of the mockup test which include an initial screening of personnel qualifications, a demonstration of equipment calibration, performing UT on specimens, and reporting results. The main purpose is to ensure UT personnel can accurately perform inspections to minimize leaks at PHE ONWJ's oil and gas facilities. The test also aims to evaluate personnel competency levels to match them with appropriate job roles.
This document outlines the procedures for conducting a mockup test for ultrasonic testing (UT) personnel recruitment at PT.Spektra Megah Semesta. It describes the general steps of the mockup test which include an initial screening of personnel qualifications, a demonstration of equipment calibration, performing UT on specimens, and reporting results. The main purpose is to ensure UT personnel can accurately perform inspections to minimize leaks at PHE ONWJ's oil and gas facilities. The test also aims to evaluate personnel competency levels to match them with appropriate job roles.
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PROCEDURE AUTHORIZATION This procedure have been generated and implemented to identify the control that shall be applied by members of staff in the department when carrying out their duties Department Authorization
Signed: Date: This confirms that this procedure has been approved for official issue and that members of staff shall complete the tasks assigned in accordance with the mechanisms defined herein Corporate Authorization (Company Director)
Signed: Date: The procedure forms part of a formal system within the company which ensure that this document is handled in a controlled manner in accordance with documented procedures. This procedure will be subject to audit as part of the company policy towards quality Quality Authorization (Quality Management Reps)
Signed: Date:
PROCEDURE REVISION Rev. Date Section Outline of Changed Authorization 0 18 October 2010 - First Issue
STATEMENT OF CONFIDENTIALITY This procedure is for controlled circulation unless stamped "Uncontrolled Copy. The documents or extracts from documents must nor be passed or copied to other companies, agents or persons without the permission of the relevant Company Directors.
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Revision No. Date Description Approved by Reviewed by Prepared by
1
October 18, 2010
Second Issue
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Daftar Isi Table of Content
Par. Uraian Par. Description Page 1 Umum 1 General 2 Ruang Lingkup 2 Scope 3 Istilah 3 Definition and Abbreviation 3.1 Istilah 3.1 Definition 4 Tanggung Jawab 4 Responsibility
4.1 Penyelenggara 4.1 Organizer
4.2 Assesor 4.2 Accesor 4.3 Witness 4.3 Witness 5 Persyaratan Umum 5 General Requirement
5.1 Persyaratan Personil 5.1 Personnel Requirement 5.2 Persyaratan Peralatan 5.2 Equipment Requirement 6 Tahapan test mock up 6 Steps of Mock up test 6.1 Spesimen 6.1 Specimen 6.2 Peralatan UT 6.2 UT Equipment 6.3 Percobaan dan Demonstrasi 6.3 Experiment and Demonstration
7 Pengujian UT dan Evaluasi cacat 7 Examination UT and Evaluation Defect
7.1 Kalibrasi Instrumen UT 7.1 Callibration of UT Equipment 7.2 Pemeriksaan Ketebalan 7.2 Thickness Measurement 7.3 Pengukuran dan evaluasi cacat 7.3 Measurement and evaluated 7.4 Pelaporan dokument 9 Report of document 8. Kriteria Penilaian 8. Assesment criteria 9. Kelulusan/Ketidaklulusan 9. Pass / Failure 10 Pemetaan Personil 10 Mapping Personnel 11 Masa Berlaku Otorisasi 11 Validation Period of Authorization
12 Review dan Revisi 12 Review and Revision
13 Referensi 13 Reference
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1 Umum 1 General UT MOCKUP Testing adalah test yang diperuntukan untuk para UT Technician ASNT LV II contractor yang akan dan atau sedang bekerja di lingkungan kilang minyak dan gas PHE ONWJ. Sebelum mereka dinyatakan qualified untuk bekerja, sebelumnya mereka harus dinyatakan lulus melalui serangkain test mock up yang akan dilaksakan oleh Inspection dept. PHE ONWJ. Prosedur mockup test ini mengatur tata cara dan bagian-bagian dari mock up test yang harus dilalui oleh UT technician ASNT LV II. Secara umum tahapan dari mock up test adalah: Penyaringan awal meliputi kualifikasi personil dan pengalaman pekerjaan dibidang NDT metode ultrasonic test. Demonstrasi kalibrasi menggunakan block kalibrasi. Melakukan pengujian ultrasonic test terhadap specimen yang telah disediakan oleh penguji. Melakukan pelaporan dan perekaman hasil pemeriksaan. Tujuan utama dari dilakukannya UT Mockup testing ini adalah untuk memastikan bahwa seluruh personil yang melaksanakan pengujian tidak merusak dengan metoda ultrasonic dilingkungan kilang minyak dan gas PHE ONWJ dapat melakukan pemeriksaan secara benar dan akurat. Dengan adanya kompetensi personil yang telah teruji melalui mockup test ini maka diharapkan kemungkinan terjadinya kebocoran dikilang minyak dan gas PHE ONWJ yang disebabkan karena factor human error dapat dieliminir.
UT MOCKUP Testing is intended for UT Technicians ASNT LV II contractor which will work or already working in PHE ONWJ oil and gas area. Before they are stated to be qualified to work, they should undergo some mockup test held by Inspection Dept. PHE ONWJ. This procedure describe about steps and parts of Mockup Test that have to be passed by UT Technician ASNT LV II. Generally, the steps of mockup test are as follow : Initial selection including personnel qualification and experience in NDT ultrasonic test. Calibration demonstration using calibration block. Perform ultrasonic test on specimen provided by assessor. Perform recording and reporting of the test result. The main purpose of Mockup test is to make sure that all NDT UT personnels working in PHE ONWJ area are able to perform the test well and accurately. So that, the probability of leak can be eliminated. The test also aims to classify the personnel competency base on their technical and non-technical skill. It is very useful to put the right man in the right place.
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Melihat perlunya mengetahui kemampuan perorangan dari para personil UT dalam melakukan berbagai jenis pekerjaan maka mockup test juga berfungsi untuk memetakan kemampuan dari para personil UT berdasarkan kemampuan teknis dan non teknis. Sehingga pemilihan personil yang akan diterjunkan untuk satu jenis pekerjaan akan lebih terarah dan pekerjaan dapat dilakukan oleh orang yang tepat (The right man at the right place)
2 Ruang Lingkup 2 Scope Secara garis besar prosedur ini antara lain mengatur tentang berbagai persyaratan- persyaratan personil yang melakukan pemeriksaan ultrasonic test, tahapan dan tata cara pelaksanaan teknis dari mockup test, criteria kelulusan peserta test, dan berbagai hal lain yang berkaitan secara teknis maupun non teknis dari penyelenggaraan mock up test. Output dari penyelenggaraan mockup test adalah legalitas dari seorang personil ultrasonic testing untuk bekeja dilingkungan PHE ONWJ.
Generally, this procedure regulates about requirements of the personnel who will perform ultrasonic test, the steps and technical implementation of mockup test. Output of the test is legality of ultrasonic test personnel to work in PHE ONWJ area.
3 Istilah 3 Definition 3.1 Istilah 3.1 Definition Berikut adalah beberapa istilah yang digunakan didalam prosedur ini berdasarkan abjadnya : The following are some definitions used in this procedure :
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ASNT LV II : Kompetensi yang dikeluarkan oleh badan standarisasi pengujian tidak merusak amerika yang harus dimiliki oleh seseorang personil UT di PHE ONWJ.
ASNT LV II : Competency issued by American Society for Non Destructive Testing that must be owned by UT personnel in PHE ONWJ. Baja Karbon : Baja yang hanya memiliki paduan utama yaitu carbon. Bagaimanapun paduan lain juga seringkali ditambahkan hanya dalam jumlah kecil seperti Cr, Ni, Mn, Si, P, Mo, dll guna meningkatkan sifat mekanik dan fisiknya.
Carbon steel : Alloy steel that has only main carbon. However other alloys are also often added only in small amounts such as Cr, Ni, Mn, Si, P, Mo, etc. in order to improve the mechanical and physical properties. Blok kalibrasi : Blok standar yang dipergunakan untuk mengkalibrasi alat UT.Jenisnya bermacam-macam berdasarkan penggunaannya.
Calibration block : Standard blocks that are used to calibrate the UT instrument. Kind vary based on usage Couplant : Media cair yang dipergunakan sebagai perantara antara material yang ingin diperiksa dengan probe/transducer dari peralatan UT sehingga gelombang ultrasonic dapat menjalar ke material.
Couplant : Liquid medium that is used as an intermediary between the material to be examined with the probe / transducer of UT equipment so that ultrasonic waves can spread to the material. Spesimen : Benda uji yang diberikan pada peserta mockup test untuk dilakukan pengujian UT dimana didalamnya terdapat/tidak cacat yang telah dibuat. Specimens: Objects test given to mockup tests participants for UT testing in which there are / are not defects that have been made. Penyelenggara : Pihak yang bertanggung jawab dalam menyelenggarakan mockup test dalam hal ini adalah PT. Spektra Megah Semesta dan disaksikan oleh PHE ONWJ.
Organizer : Responsible party in holding mockup test in this case is PT. Spektra Megah Semesta and the witness by PHE ONWJ.
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Peserta : Pihak yang berasal dari rekanan kerja PHE ONWJ dibidang pemeriksaan teknis jenis ultrasonic dan yang mengikuti seluruh rangkaian mockup test. Participant : Person who comes from working partners PHE ONWJ in technical inspection field type ultrasonic and follow the entire series of mockup test. Pitting corrosion : Bentuk dari cacat korosi yang cenderung terkonsentrasi pada satu titik sehingga membentuk lubang-lubang/sumur yang ukurannya relatif kecil. Pitting corrosion biasanya dipengaruhi oleh lingkungan, komposisi material, potensial, temperature, dan kondisi permukaan.
Internal corrosion : Cacat yang disebabkan oleh proses korosi antara media service dengan material dari peralatan (pipa,bejana tekan, dll) sehingga menyebabkan adanya pengurangan ketebalan dari sisi dalam material. Bentuk dari cacat ini cenderung tidak beraturan dan dapat dideteksi dengan menggunakan peralatan UT Pitting corrosion: Forms of corrosion defects which tend to be concentrated at one point and form a relatively small size holes. Pitting corrosion is usually influenced by the environment, material composition, potential, temperature, and surface conditions.
Internal corrosion : Defects caused by corrosion process between the media service with the materials of the equipment (piping, pressure vessels, etc.) thereby causing a reduction in the thickness of the material. The shapes of these defects tend to be irregular and can be detected using UT equipment.
4 TANGGUNG JAWAB 4 Responsibility 4.1 Penyelenggara Penyelenggara bertanggung jawab dalam mempersiapkan mockup test dan melakukan penilaian hasil test peserta. Penilaian mockup test dibuat berdasarkan akumulasi hasil nilai dari tiap-tiap
4.1 Organizer Organizers are responsible for preparing the mockup test and evaluate the results of test participants. Mockup test assessment is made based on the accumulated results of the value of the persentase bobot test. percentage weight of each test.
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4.2
Assesor Pengawas bertanggung jawab untuk melakukan arahan kepada peserta test serta mengawasi peserta yang melakukan mockup test agar tidak terjadi kecurangan pada saat test berlangsung dan memaintenance personil serta berperan sebagai monitor competence level dari personil .
4.3 Witness : Pihak yang bertanggung jawab untuk mengawasi jalannya mock up test dengan lancar. Pihak ini bisa berasal dari PHE ONWJ ataupun independent examiner
4.2 Accesor Accesor are responsible to make referrals to participants test and supervise the participants who did mockup tests to prevent cheating during the test, and can be maintenace so monitoring competence level of personil
4.3 Witness: Parties responsible for overseeing the mock-up test smoothly. Parties may come from PHE ONWJ or independent examiner 4.4 Peserta Peserta mempunyai tanggung jawab untuk mengikuti seluruh rangkaian mockup test yang telah diselenggarakan oleh pihak penyelenggara dengan sebaik-baiknya.
4.4 Participant Participants have a responsibility to follow the entire series of mockup tests that have been held by the organizers as well as possible.
5 PERSYARATAN UMUM 5 General Requirement 5.1 PERSYARATAN PERSONIL Peserta diperbolehkan untuk mengikuti mock up test dengan persyaratan awal sbb: Seluruh peserta adalah karyawan dari kontractor yang berasal dari perusahaan rekanan PHE ONWJ dan sedang menjalani kontrak NDT services dilingkungan PHE ONWJ Seluruh peserta telah memiliki kualifikasi sebagai UT technician ASNT LV II yang masih berlaku atau yang sederajat dan disertai dengan membawa sertifikat asli pada saat waktu pelaksaan test. Peserta telah memiliki pengalaman dalam melakukan pemeriksaan peralatan 5.1 Personnel Requirement Participants are allowed to participate in a mock-up test with the initial conditions as follows: All participants are employees of contractors who come from partner companies and is undergoing PHE ONWJ contract "NDT services" in PHE ONWJ area. All participants have been qualified as ASNT UT technician LV II and still valid, or its equivalent and accompanied with the original certificate at
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utama perminyakan bertekanan seperti pressure vessel, process piping, above ground tank, dan peralatan bertekanan lainnya yang berada dilingkungan kilang minyak dan gas PHE ONWJ.
the time of the test. The participants already have experience in conducting inspection of main pressurized oil equipment such as pressure vessel, process piping, above ground tanks, and other pressure equipment which are located at PHE ONWJ area.
5.2 PERSYARATAN PERALATAN 5.2 Equipment Requirement 5.2.1 Instrument UT Peralatan yang digunakan pada saat mockup test adalah type pulse-echo dengan range frekwensi kerja minimal 1 5 Mhz dan dilengkapi dengan control step gain minimal 2.0 dB atau kurang. Dilengkapi pula dengan 1 set probe (diameter 5~13 mm), dan block kalibrasi sekurang-kurangnya block V1/IIW dan Stepwedge. Seluruh peralatan yang akan digunakan dalam pelaksanaan test telah dipastikan terlebih dahulu dalam kondisi baik sehingga jalannya mockup test tidak terganggu. 5.2.2 Couplant Couplant yang digunakan pada saat mockup test sifatnya tidak mengikat. Dapat digunakan jenis Gel, CMC, oli, atau couplant sejenis yang digunakan untuk bekerja dilingkungan PHE ONWJ. Selama couplant tidak terbuat dari bahan kimia yang merusak maka couplant tersebut dapat dipergunakan. Couplant yang digunakan selama kalibrasi harus sesuai dengan couplant yang digunakan pada saat 5.2.1 UT Instrument Equipment used during mockup test is a pulse-echo type with a minimum working frequency range 1-5 MHz and comes with control step gain of at least 2.0 dB or less. Also equipped with a set of probes (diameter of 5 ~ 13 mm), and block calibration at least block V1/IIW and Stepwedge. All equipment to be used in the implementation of the test was confirmed in advance in good condition so that the course mockup test are not disturbed. 5.2.2 Couplant Couplant used during mockup test is non-binding. The type can be used is GEL, CMC, oil, or similar couplant used to working in PHE ONWJ area. As long as not made of damaging chemicals, so couplant can be used. Couplant used during calibration must be in accordance with the couplant used during examination of specimens.
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melakukan pemeriksaan specimen. 5.2.3 Blok Kalibrasi Blok kalibrasi yang digunakan sekurang- kurangnya sesuai dengan standard dari ASME section V Non Destructive Test atau sesuai dengan prosedur tertulis dari kontraktor rekanan PHE ONWJ. Jenis material blok kalibrasi yang digunakan harus sama dengan material yang akan digunakan sebagai mock up test. 5.2.3 Calibration Block Calibration blocks are used at least in accordance with the standards of ASME section V "Non-Destructive Test" or in accordance with written procedures of the contractor partners PHE ONWJ. This type of calibration block material used must be the same as the material to be used as a mock-up test specimen.
6 Tahapan test Mock up :
6. Steps of Mock Up Test :
Persiapan test mock up meliputi persiapan dari segi teori dan teknik seperti persiapan specimen dan peralatan yang digunakan serta persiapan dari segi non teknis seperti tata tertib dalam mockup test dan percobaan/demonstrasi. Aturan tertulis harus disiapkan dan diberikan kepada setiap peserta sebelum mockup test dimulai. Pengawas harus memastikan bahwa peserta telah membaca tata tertib dan arahan secara jelas mengenai mockup test. Secara garis besar arahan tertulis mengatur tentang tata tertib, syarat-syarat awal mockup test, langkah-langkah dan deskripsi mockup test, criteria penilaian, dan beberapa hal lainnya yang perlu ditambahkan demi kelancaran acara mockup test.
Preparation of mockup test includes the preparation of technical aspect such as specimen preparation and the equipment used and the preparation of non-technical aspects such as rule in the mockup test and experiment / demonstration.
Written Practice directives must be prepared and given to each participant before the mockup test begins. Supervisors must ensure that participants have read the rules and directives clearly about the mockup test. Broadly written directives governing order, the terms of the initial mockup tests, measures and descriptions mockup tests, assessment criteria, and a few other things that need to be added for smooth event of mockup test.
6.1 Specimen 6.1 Specimen Spesimen yang digunakan adalah spesimen Specimens used were plate-shaped
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berbentuk pelat ataupun pipa/tubular dengan material baja carbon steel yang telah dilengkapi dengan cacat buatan yang telah dibuat didalam material. Cacat material yang harus dideteksi oleh peserta adalah cacat typical yang seringkali dijumpai diperalatan kilang minyak dan gas PHE ONWJ diantaranya adalah internal corrosion, pitting corrosion, laminasi,dan porosity. Setiap specimen yang akan diujikan memiliki nomer identitas yang sebelumnya telah didata dan telah memiliki kunci jawaban berupa hasil gambar film radiografi lengkap dengan ukuran serta kedalaman.. Kunci jawaban ini harus disimpan dengan aman dan tidak diperbolehkan untuk dikeluarkan kecuali untuk memeriksa hasil ujian dari peserta Mock up test. Seluruh peserta yang telah mengikuti baik yang telah dinyatakan lulus test ataupun tidak, tidak diperbolehkan untuk melihat dan meminta kunci jawaban. Hanya bagian dari PHE ONWJ yang mempunyai akses terhadap kunci jawaban tersebut.
specimen or pipe / tubular steel with carbon steel material which has been fitted with an artificial defect was created in the material. Material defects which must be detected by the participants are typical defects that are often encountered in oil and gas refineries equipments PHE ONWJ include internal corrosion, pitting corrosion, laminations, and porosity. Each specimen to be tested has a ID number that has previously been recorded and there is an answer key in the form of a complete radiographic film images with the size and depth. This answer key must be stored safely and not allowed to be issued except to check the test results of participants Mockup test. All participants who have attended both of which have passed the test or not, are not allowed to see and ask for an answer key. Only part of the PHE ONWJ who had access to answer keys.
6.2 PERALATAN ULTRASONIC TEST 6.2 ULTRASONIC TEST EQUIPMENT Untuk persyaratan peralatan ultrasonic yang digunakan selama mockup test, peralatan ultrasonic disiapkan terlebih dahulu oleh penyelenggara guna menghindari terjadinya kecurangan dalam proses kalibrasi alat. Peserta akan masuk keruangan tanpa membawa alat UT dan alat UT sudah berada didalam ruangan dan disiapkan terlebih dahulu oleh penyelenggara.
For the requirements of ultrasonic equipment used during mockup test can be seen in 4.2.1. Ultrasonic equipment prepared in advance by the organizers in order to avoid fraud in the process of instrument calibration. Participants will bring the equipment into a room without UT equipment and UT equipment are already in the room and prepared in advance by the organizers.
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6.3 PERCOBAANDAN DEMONSTRASI 6.3 Experiment and Demonstration Percobaan dan demonstrasi wajib dilakukan sebelum mock up test diputuskan untuk dilakukan. Tujuan dari dilakukannya percobaan dan demonstrasi adalah untuk memastikan bahwa specimen yang digunakan telah diinspeksi sebelumnya dan dipastikan cacat-catat yang terdapat pada specimen telah valid untuk digunakan menjadi specimen resmi mockup test. Selain itu tujuan dari percobaan dan demonstrasi adalah untuk menentukan serta memperkirakan waktu yang dibutuhkan untuk peserta dalam melakukan mock up test. 7. Pengujian UT dan Evaluasi cacat Experiments and demonstrations must be conducted before a mockup test was decided to do. The purpose of doing experiments and demonstrations is to ensure that the specimens used had been previously inspected and ascertained that there were defects noted in the specimens have been valid to use as the official mockup test specimen. In addition the purpose of the experiment and demonstration is to determine and estimate the time required for participants in conducting a mockup test.
7. Examination and Evaluation
7.1 KALIBRASI INSTRUMENT UT 7.1 Callibration of UT Equipment Sebelum melakukan pemeriksaan peserta mengkalibrasi peralatan UT nya terlebih dahulu. Peserta tidak diperkenankan membawa alat UT sendiri. Alat UT akan disiapkan oleh penyelenggara dan selalu dipastikan bahwa settingan alat UT sudah diacak terlebih dahulu parameternya setelah digunakan oleh peserta sebelumnya sehingga dapat dipastikan bahwa peserta yang melakukan test telah melakukan kalibrasi dengan sebenarmya dan sesuai dengan kemampuannya. Kalibrasi dilakukan dengan menggunakan blok kalibrasi sesuai persyaratan di 4.2.3. Setiap kalibrasi akan diberi waktu paling lama 20 menit.
Before conducting the examination participants calibrate his UT equipment first. Participants are not allowed to bring their own UT equipment. UT equipment will be prepared by the organizers and always ensured that the setting is randomized after the first parameter is used by the previous participants so that to ensure that participants have performed the calibration according to his ability. Calibration is performed using a calibration block according to the requirements in 4.2.3. Each calibration will be given a maximum of 20 minutes. 7.2 Pemeriksaan Ketebalan Specimen 7.2 Examination of Specimen Thickness Pemeriksaan ketebalan specimen dilakukan dengan teknik scanning dengan laju scanning maksimal 150mm/detik dengan Examination of specimen thickness is done by scanning technique with a maximum scanning rate 150
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overlap minimal 10% dari diameter probe yang digunakan. Scanning dilakukan pada seluruh permukaan specimen. Pencatatan ketebalan specimen hanya dilakukan untuk ketebalan material maksimum dan minimum. mm/second with overlap of at least 10% of the diameter of the probe used. Scanning performed on the entire surface of the specimen. Recording of specimen thickness is only done for the maximum and minimum thickness of material. 7.3 Pengukuran dan Evaluasi Cacat 7.3 Measurement and Evaluation of Defect Apabila terindikasi adanya cacat didalam specimen maka peserta diharuskan melakukan pengukuran dan evaluasi terhadap cacat dengan metode ekualisasi ataupun 6dB drop. Pengukuran dan evaluasi cacat meliputi sekurang-kurangnya sbb: Jenis cacat dan pemetaannya. Posisi cacat pada specimen, dimana pada specimen pelat dapat menggunakan koordinat x, y, z sedangkan pada specimen tubular dapat menggunakan arah jarum jam (0, 3, 6, 9 oclock) Ukuran cacat (Panjang dan lebar atau diameter cacat). If there is indication of a defect in the specimen then the participant is required to perform the measurement and evaluation of defect by the method of equalization or 6dB drop. Measurement and evaluation of defects include at least the following: Types of defects and mapping. The position of defects on the specimen, where the specimen plate can use the coordinates x, y, z while in the tubular specimen can use a clockwise direction (0, 3, 6, 9 o'clock). Size of defect (length and width or diameter of the defect).
7.4 PELAPORAN DAN DOKUMENTASI 7.4 Report and Documentation Setelah peserta melakukan pemeriksaan ketebalan serta melakukan evaluasi dan pengukuran cacat, peserta akan melanjutkan mockup test dengan membuat laporan hasil pemeriksaan spesimen. Format laporan telah disiapkan oleh pihak penyelenggara dalam bentuk soft copy. Pelaporan dalam hal ini dilakukan dengan menggunakan komputer yang telah disediakan oleh pihak penyelenggara. Peserta tidak diperkenankan melakukan After the participants performed the thickness examination, defect measurement and evaluation, participants will continue to make a mockup test specimen examination report. Format of the report has been prepared by the organizers in the form of soft copy. Reporting in this case is done using a computer that has been provided by the organizers. Participants are not allowed to do their own
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pelaporan dengan menggunakan komputer sendiri maupun melakukan penyimpanan data terhadap jawabannya. Parameter essensial yang tertuang didalam sistem pelaporan meliputi: Jenis alat serta parameter settingan alat UT yang digunakan pada waktu melakukan pemeriksaan. Hasil pemeriksaan ketebalan. Deskripsi dan evaluasi pemeriksaan cacat. Format pelaporan dapat dilihat pada lampiran. Seluruh pelaporan yang telah selesai harus disimpan di dalam folder khusus untuk mockup test.
reporting using a computer and perform data storage on the answer. Essential parameters are contained within the reporting system include: The type of equipment and parameter setting that used at the time UT inspection. Results of thickness. Description and evaluation of defect inspection. Reporting format can be found in appendix. The whole reporting that has been completed must be deposited in a special folder for the mockup test.
8. KRITERIA PENILAIAN 8. Assessment Criteria Setiap peserta diharuskan untuk mendemonstrasikan kemampuan mereka melakukan pemeriksaan UT dalam hal pemeriksaan ketebalan dan mengidentifikasi cacat. Selain itu penilaian juga berkaitan dengan kemampuan peserta dalam melakukan pelaporan yang baik dan benar. Semua rangkaian mockup test dilakukan dalam batas waktu yang ditentukan. Waktu yang sediakan untuk melaksanakan mockup test maksimal 120 menit tiap satu orang peserta. Dimana tiap peserta wajib untuk melakukan pemeriksaan UT terhadap 3 jenis specimen yang berbeda. Criteria penilaian dalam mockup test sangat bergantungan dari tiga faktor utama mockup test dimana masing- masing rangkaian utama tersebut mempunyai bobot penilaian yang berbeda- beda. Bobot penilaian dari masing-masing rangkaian utama mockup test adalah sbb: Seting dan Kalibrasi alat UT yang digunakan memiliki bobot 20%.
Each participant is required to demonstrate their ability to perform the examination in terms of UT thickness examination and identify defects. In addition the assessment also relates to the ability of the participants in doing good reporting and correct. All steps of mockup tests carried out within the specified time limit. Provide time to carry out the mockup test a maximum of 120 minutes per one participant. Where each participant is obliged to perform UT of three different types of specimens. Assessment criteria in the mockup test is very dependent of the three main factors mockup test in which each of the primary step has a weighting of different assessment. Assessment weighting of each of the main step of mockup test is as follows: Settings and Calibration of UT equipment used has a weight of
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Pemeriksaan specimen mockup test memiliki bobot 60%. Sistem pelaporan memiliki bobot 20%. Nilai akhir penilaian merupakan akumulasi dari factor utama diatas. Angka minimal dari kelulusan adalah 70. Dibawah angka 70 maka peserta akan gagal. Nilai akhir ini nantinya akan digunakan sebagai acuan para peserta untuk memetakan kemampuan personil UT. Lebih jelas tentang pemetaan personil dapat dilihat pada bab 10.
20%. Examination of mockup test specimen has a weight of 60%. The reporting system has a weight of 20%. The final assessment score is the accumulation of the main factors above. The minimum passing score is 70. If the score is below 70 then participants will fail. This final score will be used as a reference for participants to map out the ability of UT personnel. More details on mapping personnel can be seen in chapter 10. 9. KELULUSAN 9. Graduation Kelulusan peserta bergantung dari nilai akhir test dimana apabila nilai akhir diatas 70 maka peserta dianggap telah lulus dari mockup test. Kelulusan dibagi menjadi beberapa kategori dimana kategori inilah yang digunakan sebagai acuan dalam pemetaan personil. Graduation of the final value depends on the final score which if the final score above 70 then the participant is deemed to have graduated from the mockup test. Graduation is divided into several categories where the categories were used as reference in mapping personnel. 9.1 KETIDAKLULUSAN 9.1 Failure Ada beberapa factor yang menyebabkan peserta tidak lulus dari test mockup ini. Factor tersebut adalah: Peserta dinyatakan melakukan kecurangan selama proses mockup test berlangsung. Peserta mempunyai nilai akhir dibawah 70 Peserta melanggar tata tertib dalam pelaksanaan mockup test. Setiap personil yang dinyatakan tidak lulus akan diberikan kesempatan untuk mengikuti test mockup kembali secepat- cepatnya yaitu dalam jangka waktu minimal 3 bulan pertanggal mockup test dilaksanakan. Diharapkan waktu yang There are several factors that cause the participant does not pass the mockup test: Participants expressed cheating during the mockup test. Participants have a final grade below 70. Participants violating the rule of the mockup test. Every worker who did not pass will be given the opportunity to follow the mockup test again as soon as possible within a period of at least 3 months as of mockup tests carried out. The time given is useful for participants who did not pass in order to enhance their
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diberikan berguna bagi para peserta yang tidak lulus untuk dapat meningkatkan kemampuan mereka dalam mengikuti mockup test berikutnya. ability to follow the next mockup test.
10 PEMETAAN PERSONIL 10 Mapping Personnel Tujuan dari pemetaan personil adalah untuk menilai kemampuan personil UT dari yang paling baik hingga menengah. Kemampuan tersebut meliputi kemampuan melakukan pemeriksaan UT dengan akurat serta kemampuan personil dalam membuat laporan dengan benar dan jelas. Apabila personil telah dipetakan, maka hal ini berguna kedepannya untuk menentukan bobot pekerjaan yang akan diberikan kepada masing-masing personil serta berguna untuk pemilihan komposisi team yang akan diberangkatkan berdasarkan bobot dan urgensi pekerjaan. Dimana idealnya dalam satu team diharuskan untuk saling menutupi kekurangannya satu sama lain. Penilaian dibagi menjadi beberapa kategori yang menggambarkan kemampuan personil secara keseluruhan. Adapun tingkatan kemampuan personil dikategorikan sesuai dengan yang tertera pada table berikut:
The purpose of mapping personnel is to assess the ability of UT personnel from best to medium. These capabilities include the ability to perform an accurate examination of UT and the ability of workers in making the report correctly and clearly. If the personnel have been mapped, then it is useful in the future to determine the work load to be given to each personnel as well as useful for the selection of the composition of the team who will be dispatched based on the load and urgency of work. Ideally in a team are required to cover each other drawbacks to each other. Assessment is divided into several categories that describe the ability of personnel as a whole. The level of skills of personnel categorized as stated in the following table:
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KATEGORI PERSONIL DEFINISI Kategori (A) Personil mempunyai kemampuan dalam melakukan pemeriksaan ultrasonic dengan akurat. Dalam hal pelaporan personil juga memiliki kemampuan mengerjakan laporan dengan baik dan benar Kategori (B) Personil mempunyai kemampuan melakukan pemeriksaan ultrasonic dengan akurat namun kurang baik dalam hal pembuatan laporan.
PERSONNEL CATEGORY DEFINITION Category (A) Personnel has the ability to perform accurate ultrasonic examination. In terms of reporting workers also have the ability to do well and correct report Category (B) Personnel has the ability to perform an ultrasonic inspection with accurate but less well in terms of making the report.
Pemetaan personil juga tidak terbatas dari kemampuan dan kompetensi namun juga dalam hal perilaku. Perilaku disini mempunya arti yang cukup luas dimana dapat diartikan perilaku dalam hal keselamatan selama bekerja dan perilaku dalam hal tanggung jawab terhadap pekerjaan, Bagaimanapun yang dapat menilai perilaku personil selama ia bekerja adalah orang yang mengontrol pekerjaan mereka selama dilapangan yaitu QA/QC Inspector ataupun coordinator dari perusahaan tempat pekerja tersebut bekerja. Sehingga saran dan pertimbangan dapat dibuat pula berdasarkan informasi dari kedua pihak diatas.
Mapping personnel is also not limited to the capabilities and competencies, but also in terms of "behavior". The behavior here has general meaning in which the behavior can be interpreted in terms of safety during the work and behavior in terms of responsibility to the job, however the person that can assess the behavior of workers during work is a person who controls their job over the field that is QA / QC Inspector, or coordinator of company where employees are working. So the recommendations and considerations can be made also based on information from both sides above.
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11 MASA BERLAKU OTORISASI 11 Validation Period of Authorization Peserta yang sudah lulus mockup test akan diberikan ijin/otorosisasi untuk bekerja difasilitas kilang minyak PHE ONWJ dan valid selama kurun waktu 1 tahun. Apabila otorisasi tersebut habis masa berlakunya maka pekerja wajib melakukan mockup test kembali untuk mendemonstrasikan kemampuan kompentensi pekerja. Participants who have passed the test will be given authorization to work in PHE ONWJ facilities and is valid for a period of 1 year. If the authorization has expired then the worker must make a mockup test again to demonstrate the competence of workers.
12 REVIEW DAN REVISI 12 Review and Revision
13. Dalam hal adanya perubahan yang berakibat terhadap efektifitas dari penyelenggaran mockup test dimana dibutuhkan adanya revisi dari prosedur ini, maka prosedur ini dapat di revisi sesuai dengan kebutuhan dan keadaan yang relevan pada waktu yang akan datang. Referensi: In the event of any changes that led to the effectiveness of organizing mockup test which required a revision of this procedure, this procedure can be revised in accordance with the needs and circumstances relevant at the next time.
13.Reference :
ASME BOILER AND PRESSURE VESSEL SECTION V Non Destructive Test Examination ASME BOILER AND PRESSURE VESSEL SECTION V Non Destructive Test Examination PHE ONWJ PROCEDURE NO. xxxxx Piping and Pressure Vessel Inspection in PHE ONWJ PHE ONWJ PROCEDURE NO. xxxxx Piping and Pressure Vessel Inspection in PHE ONWJ Piping Inspection Strategy Piping Inspection Strategy for piping and pressure vessel top side inspection Piping Inspection Strategy Piping Inspection Strategy for piping and pressure vessel top side inspection
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scanning level 4,5 Proper reporting 2 5 Scanning 5,1 Proper selecting probes 2,5 5,2 Understand the use of probes 2,5 5,3 Proper scanning speed 2,5 5,4 Proper scanning pattern 2,5 Identification of correct
indications 6,1 Proper 100% exam. covered 2,5
Proper differentiate false & true
indication 2,5
6,3 Proper identify defect compare to the master 7 Sizing of the indications 7,1 Proper method of length measurement 2,5 7,2 Proper measure the indication length 7,5 8 Identifying type of indication 8,1 Understanding type of indication 5 8,2 Proper differentiate type of indication 5 Evaluation according to
Procedure / Code 9,1 Proper interpret the acceptance 5
9,2 Proper decide accept / reject 5 10 Report Writing 10,1 Proper filling all the report Form 2,5 10,2 Proper drawing the sketch 2,5 10,3 Proper numbering the report 2,5 10,4 Signed and date 2,5