MATERI TRAINING SINGKAT

PROSES DASAR OVERHAUL POMPA CENTRIFUGAL

Disusun oleh Deden Wlden BSD 22-05-2012

INCOMING

OVERHAUL FLOW CHART

DISASSEMBLY

CLEANING

INSPECTION

REPLACE

REPAIR

FABRIKASI

CUSTOMER SUPPLIED

ASSEMBLY

PACKAGING

REPORT

SHIPPING

HOW TO RUN THE FLOW CHART ?????

SIAPA PENGENDALI DARI FLOW CHART UTK SUBJEK BERIKUT? - SKEDUL/PROGRES - TEKNIS/QUALITY - BUDGET - SAFETY S.O.P/SRP/QI/JOB DESC. DARI TIAP KEGIATAN FORM-FORM YG DIPERLUKAN SIAPA2 SAJA YANG AKAN MELAKSANAKAN INSTRUKSI UNTUK MENJALANKAN STEP OF WORK

 INCOMING INSPECTION

PROSES DASAR OVERHAUL POMPA CENTRIFUGAL

DISASSEMBLY CLEANING , CHEMICAL OR MECHANICAL DETAIL INSPECTION REPAIR/RECONDITION FABRIKASI REPLACEMENT PARTS ASSEMBLY AND BALANCING ROTOR ASSEMBLY PUMP PACKAGING AND SHIPPING PREPARE REPAIR REPORT

INCOMING INSPECTION
HAL-HAL YG PERLU DIPERHATIKAN PERHATIKAN PERINTAH KERJA CEK DATA PENGIRIMAN DAN FISIK BARANG PERIKSA KONDISI BARANG SECARA UMUM DAN QUANTITYNYA LAPORKAN KE BAGIAN MARKETING KALAU DITEMUKAN NON-CONFORMITY DOKUMENTASI/FOTO Note: DIPAKAI JUGA SBG REFERENSI PENGIRIMAN

DISASSEMBLY
MENGENAL EQUIPMENT/POMPA YG AKAN
DIOVERHAUL. PERHATIKAN PERINTAH KERJA/SRP SIAPKAN PERALATAN KERJA PERHATIKAN KONDISI YG ABNORMAL PERHATIKAN PERINGATAN SAFETY MARKING/TAG TAKE FOTO

CLEANING
CHEMICAL CLEANING
SOLVENT DEGREASER RUST/SCALE REMOVER PAINT REMOVER

MECHANICAL CLEANING
BLASTING , WET OR DRY ( MEDIA AL-OX , GLASS BEAD ) VIBRATORY CLEANING

DETAIL INSPECTION
JENIS-JENIS INSPECTION VISUAL
DIMENSIONAL FUNCTIONAL NDT ( utk pompa jarang diterapkan ) - FPI - MPI - UT

FABRIKASI
HAL-HAL YG PERLU DIPERHATIKAN GEOMETRI, bentuk dan ukuran MATERIAL SPECIFICATION, certificate required PROSES FABRIKASI

 GEOMETRI ( bentuk dan ukuran )

- Memahami Technical Drawing dan notasinya. - Memahami prinsip Metrology - Toleransi - Kekasaran Permukaan - Dimensi relatif terhadap dimensi lain (run-out, kesejajaran dll )

REPAIR/RECONDITION
MENGENAL PROSES REPAIR DASAR JOINING PROCES ( WELDING, BRAZING ) COATING PROCES (ELECTRO PLATING, METAL SPRAY ) MACHINING PROCES ( TURNING, MILLING, GRINDING , DRILLING ) HEAT TREATMENT ( HARDENING, ANEALING, TEMPERING , STRESS
RELIEVE )

FABRIKASI - REPAIR
BISA DILAKUKAN DI:
SHOP SENDIRI VENDOR

APA YG PERLU DIPERHATIKAN BILA KE VENDOR ?

QUALITY TURN AROUND TIME COMPETITIVE PRICE

VENDOR QUALITY REQUIREMENT

Apakah memiliki : 1. Pocedure ( SRP ) 2. Kalibrasi 3. Material control 4. Mempunyai Equipment 5. Reporting 6. Safety Procedure Sebagian bisa di endorse : Kalibrasi, SRP , Safety dan Reporting.

PACKAGING AND SHIPPING

PRESERVASI SAFE FOR TRANPORTING MENARIK SECARA VISUAL ASURANSI

REPORTING
MINIMUM CONTEN AS RECEIVED INSPECTION DIMENSIONAL INSPECTION BALANCING REPORT MATERIAL CERTIFICATE , if requested

BALANCING ROTOR
MEMAHAMI PRINSIP DASAR BALANCING PROCES. MEMAHAMI REFERENSI, ISO-1940 dan API

Balancing : Proses mengurangi atau menambah masa utk mengurang masa yg tdk merata.
TEKNIS BALANCING ROTOR INDIVIDUAL, perlu mandrel PROGRESSIVE BALANCE ROTOR/FINAL BALANCE ( satu kali )

INDIVIDUAL BALANCING, kapan ?

- IMPELLER MAJOR REPAIR - NEW IMPELLER - MENGURANGI UNBALANCE WAKTU FINAL BALANCE.
Impeller

Mandrel shaft

Balancing Machine Bearing

PROGRESSIVE BALANCING
CONTOH ROTOR POMPA 4 STAGES
1 3

Shaft 2

Impeller

Final balancing

BERDASARKAN PENGALAMAN
UNTUK OVERHAUL POMPA DGN IMPELLER YG MASIH BAIK CUKUP DILAKUKAN FINAL BALANCING/SEKALI BALANCING ROROT SET.

TYPE OF UNBALANCE
Definisi Unbalance : Distribusi masa yg tdk merata terhadap sumbu rotasi rotor

Type Unbalance STATIC UNBALANCE COUPLE UNBALANCE DYNAMIC UNBALANCE

STATIC UNBALANCE
Terjadi bila : Sumbu Inersia bergeser sejajar dengan sumbu shaft
Unbalance Unbalance

Principle Inertia Axis

C.G

Shaft Axis

Type ini utamanya terjadi pada part bentuk disk yg tipis, misalnya : flywheel, turbine disk Can be corrected by single plane
Priciple Inertia Axis = Sumbu Inersia C.G = Center of Gravity

COUPLE UNBALANCE
Terjadi bila : Sumbu inersia berpotongan dgn sumbu shaft pada posisi C.G
C.G

Shaft Axis
Unbalance

Principle Inertia Axis

Cannot be corrected by single correction plane

DYNAMIC UNBALANACE
Terjadi bila : Sumbu inersia tidak sejajar maupun berpotongan dgn sumbu shaft ( kondisi paling sering terjadi )

Unbalance

C.G

Unbalance

Cannot be corrected by single plane

INDIVIDUAL BALANCING

ROTOR BALANCING

25

ROTOR BALANCING

26

ADVANCE TRAINING UNTUK BALANCINGVIBARI DIPERLUKAN SPECIALIST