Prosedur Kalibrasi

PT.KOKAI INDO ABADI.
F i l e C o d e ： KK-QP-_ _-_ _
Rev: 0 Calibration Procedures
Rev Date: 2019.11.01 A0 Page：1-2
1. Purpose
Untuk memeriksa keakuratan instrumen dan menentukan ketertelusuran pengukuran. Untuk
meningkatkan keakuratan alat ukur. Sedangkan alat ukur yang akurat meningkatkan kualitas
produk.
2. Scope
Buku ini dikhususkan pada pembahasan prosedur kalibrasi suatu instrument.
3. Responsibilities
3.1. Quality Department yang bertanggung jawab untuk kegiatan kalibrasi alat ukur
3.2. Quality Department is responsible for all aspects of quality control and inspection work and
implement the quality examination of manufactured products for inventory checks.
4. Procedure
4.1. Before Receiving
4.1.1. Marketing\Sales engineer will survey to customer plant before receiving repair service
for checking of goods condition or if sufficient by phone/email.
4.1.2. If needed the company will send the technical person to checking of goods condition
4.1.3. Make the review the product before receiving repair servicing and communicated to all
related division.
4.1.4. Processing sales order
4.2. Valve Receiving

4.2.1. Upon receipt of the valve from service, record the nameplate details
4.2.2. Compulsory to provide all the necessary information for the goods and conditions of the
goods at that time.
4.2.3. Material Safety Data Sheet (MSDS) goods to be reconditioned.
4.3. Disassembly Procedure

4.3.1. Where required, valve parts shall be marked for orientation purposes this ensuring rebuilt
valves are correctly assembled.
4.3.2. Remove the actuator, if applicable, and comply with PT KOKAI Standard actuator
devices repair test procedures.
4.3.3. Remove Gearbox, ONLY if there is a fault or the unit is in a poor conditions, and strip
into component parts.
4.3.4. Remove lock nut & hand wheel if applicable.
4.3.5. Remove retaining nut, drive nut & bearings, if applicable.
4.3.6. Loosen gland bolts to gain access to gland packing.
4.3.7. Remove gland packing.
4.3.8. Remove bonnet nuts & studs.
4.3.9. Lift off bonnet, stem and gate.
4.3.10. Hard Stamp one side of gate with an identification mark in conjunction with the
corresponding valve port.
4.3.11. Remove Stem , gland & gland plate from bonnet.
4.3.12. Remove bonnet gasket.
4.3.13. Remove backseat bushing if damaged or if severe corrosion is evident in its locality.
4.3.14. Remove body seat ring if damaged or if service corrosion is evident in its locality.
4.3.15. If there is damage to the disc and the seat and re-welding required is refer to Repair
Welding Procedure PT.KOKAI.
4.4. Cleaning Procedure

4.4.1. Small components or precision components shall be “buffed” clean or washed in a
suitable degreaser.
4.4.2. Large components manufactured in steel out of a base material only, if not coated, may be
aqua blasted or shot blasted.
4.4.3. Large components manufactured in steel with a coating may be aqua blasted.
4.4.4. Where cleaning equipment is not available, the components shall be hand cleaned using a
wire brush, emery clothes and rags.
4.5. Machining and Lapping

4.5.1. Based on inspection report, valve will be re-machine to restothethe valve to its original
dimension. Rebuild by welding where necessary
4.5.2. Machine lap both side of the disc.
4.5.3. Polish the gate with diamond abrasive to attain proper surface finish.
4.5.4. Replace the gate with new gate if necessary.
4.5.5. Lap the seat of the valve for proper sealing contact with the gate. Rebuilt seating surface
where necessary by deposit welding using material equivalent to the original seat. Ample
allowance for valve wear is always ensured.
4.5.6. Flange faces are rebuild and re-machined where necessary to comply with the relevant
standard of finish and dimensions for flange thickness and face-to-face.
4.6. Inspection Procedure

4.6.1. All components shall be inspected and the worksheet details completed stating any
additional work e.g. lapping/machining/welding.
4.6.2. With reference to the PT KOKAI Repair Schedule, where components are deemed
unserviceable, the applicable customer’s representative responsible for controlling the
valve maintenance work shall be notified of the unserviceable parts.
4.7. In progress Storage Procedure

4.7.1. The disassembly valve, actuator & accessories shall be loosely assembled,where possible,
to prevent loss or damage to the components and stored in a secure area under the control
of the PT KOKAI Valve Technician (s ), pending instructions from the customer.
4.8. Assembly Procedure

4.8.1. Replacements parts, where applicable, shall be checked for suitability.
4.8.2. Extra work i.e. lapping/machining/welding, shall be carried out prior to assembly.
4.8.3. The procedure for assembly shall be in reverse order of the disassembly procedure.
4.8.4. All gaskets shall be lightly coated in a nickel based greased or equivalent.
4.8.5. All soft seals shall be lightly coated in a silicon based greased where the manufacturer has
not supplied a lubricant in the seal kit.
4.8.6. For packaging procedure refer to “Work Instruction of Warehouse Management
Regulation”
5. References
5.1. Welding Repair Procedure
5.2. API 6DR Recommended Practice for the Repair and Remanufacture of Pipeline Valves
5.3. Contract Review Procedure
6. Attached
6.1. Inspection Test and Plan of Repair.
6.2. Flowchart
Requirements
QC :
Rockwell Hardness Tester, Hydraulic Pressure Multi Testing, Semi Automatic Impact Testing, Impact
Sample Notch Broaching Machine, Coating Thickness Gauge, Magnetic Particle Inspection Electic Yoke,
Pressure Gauge, Pressure Transducer, Torque Wrench, Digital Multimeter, Vernier Caliper,
Amperemeter, Voltmeter, Temperature Reading (Furnace), Thermometer Type K (PWHT), Vernier
Depth Caliper, Micrometer, Height Gauge, Infrared Thermometer, IR Thermometer,
References :
Menurut ISO 9001:2008
Setiap perusahaan yang memiliki alat ukur yang hasil pengukurannya memberikan bukti kesesuaian
terhadap persyaratan maka wajib dijaga dan dikendalikan dengan cara kalibrasi secara berkala untuk
menjamin hasil pengukuran yang valid.
YANG HARUS DIBUAT :
1. Daftar alat ukur

2. Jadwal kalibrasi alat ukur
3. Bukti kalibrasi alat ukur (sertifikat)
ALAT UKUR YANG HARUS DI KALIBRASI
1. Alat baru
2. Suatu perangkat setiap waktu tertentu
3. Suatu perangkat setiap pengunaan waktu tertentu (jam operasi)
4. Ketika suatu instrument mengalami tumbukan/getaran yang berpotensi merubah kalibrasi
5. Ketika hasil pengamatan dipertanyakan

Prosedur Kalibrasi

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PT.KOKAI INDO ABADI.

Rev: 0 Calibration Procedures

Rev Date: 2019.11.01 A0 Page：1-2

4.2. Valve Receiving

4.3. Disassembly Procedure

4.4. Cleaning Procedure

4.5. Machining and Lapping

4.6. Inspection Procedure

4.7. In progress Storage Procedure

4.8. Assembly Procedure

Menurut ISO 9001:2008

YANG HARUS DIBUAT :

1. Daftar alat ukur

ALAT UKUR YANG HARUS DI KALIBRASI

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