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  • Trouble Inspection Report: PT - Komipo Pembangkitan Jawa Bali Pltu Tanjung Jati B Unit #3&4

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    Aris Suprapto
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    1. The reclaim water tank pumps A and B at the Tanjung Jati B #3&4 Coal Fired Power Plant were experiencing high noise and vibration. 2. An inspection found that the shaft bearings, oil seals, and mechanical seals of the pumps were worn out due to long-term operation. 3. The proposed actions are to dismantle the pumps and restore the components by measuring clearances, balancing the impeller and casing, and replacing worn parts.

    Original Description:

    Gypsum slurry Centrifugal pump

    Original Title

    Reclaim Water Tank

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    1. The reclaim water tank pumps A and B at the Tanjung Jati B #3&4 Coal Fired Power Plant were experiencing high noise and vibration. 2. An inspection found that the shaft bearings, oil seals, and mechanical seals of the pumps were worn out due to long-term operation. 3. The proposed actions are to dismantle the pumps and restore the components by measuring clearances, balancing the impeller and casing, and replacing worn parts.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    9 views10 pages

    Trouble Inspection Report: PT - Komipo Pembangkitan Jawa Bali Pltu Tanjung Jati B Unit #3&4

    Uploaded by

    Aris Suprapto
    1. The reclaim water tank pumps A and B at the Tanjung Jati B #3&4 Coal Fired Power Plant were experiencing high noise and vibration. 2. An inspection found that the shaft bearings, oil seals, and mechanical seals of the pumps were worn out due to long-term operation. 3. The proposed actions are to dismantle the pumps and restore the components by measuring clearances, balancing the impeller and casing, and replacing worn parts.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 10

    Doc Ref.

    KPJB-
    PT.KOMIPO PEMBANGKITAN JAWA BALI
    PLTU TANJUNG JATI B UNIT #3&4 Form
    KPJB-
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    No. Doc ITRN-61401-03-2014-03 Date 26 March 2014 System Dewatering System

    Inspecte
    Subject Reviewed
    SR No. 1008434, 100827 Approved
    and 1008169 Reclaim water tank pump A & B
    d by by by

    Trouble Reclaim water tank A & B noise and vibration high (00DS-P978A/B)
    Equipment

    Occurrence 24 March 2014, 13 March 2014, 4 March 2014


    Date

    Operation Operation Status


    Status Reclaim Pump
    Operation Status
    Unit A Unit B
    Noise √ √
    Vibration √ √
    Temperature √ √

    Bearing ( SKF6310 / C3 )
    Equipment Unit A Unit B
    ND NDE ND NDE
    Bearing
    Damage Damage Damage Damage

    Oil Seal (Ø=50 72.12)


    Equipment Unit A Unit B
    ND NDE ND NDE
    Oil Seal
    Damage Damage Damage Damage

    Mechanical seal (Ø=50 72.12)


    Equipment Unit A Unit B
    Mechanical Seal Ok Damage

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    Trouble Status 1. There are 2 pumps that the refer the above table
    2. The shaft bearing bushings of pump are worn out
    Unit A Unit B
    Equipment
    Commissioning Existing Commissioning Existing

    Bearing ND NDE ND NDE ND NDE ND NDE


    Bushing Ø50 Ø50 Ø50 Ø50 Ø50 Ø50 Ø50 Ø50
    +0.02 +0.02 -0.03 -0.05 +0.02 +0.02 -0.06 -0.05

    3. The shaft mechanical seal of pump are worn out


    Unit A Unit B
    Equipment
    Commissioning Existing Commissioning Existing
    Mechanical
    Seal Ø50 -0.05 Ø49.40 Ø50 -0.05 Ø48.90

    4. The shaft oil seal of pump are worn out


    Unit A Unit B
    Equipment
    Commissioning Existing Commissioning Existing
    ND NDE ND NDE ND NDE ND NDE
    Oil Seal Ø50 Ø50 Ø50 Ø50 Ø50 Ø50 Ø50 Ø50
    +0.02 +0.02 -0.03 -0.05 +0.02 +0.02 -0.06 -0.05

    5. The shaft run out of pump are worn out


    Equipme Unit A Unit B
    nt Bearing Bearing Bearing Bearing
    Impeller NDE DE Coupling Impeller NDE DE Coupling
    0.40 0.00 0.00 0.05 0.42 0.00 0.00 0.05
    Run Out
    micron micron micron micron micron micron micron micron

    Action to be 1. Dismantling the pumps and measuring the gap clearance from shaft, check
    taken balancing impeller and volute casing.

    Cause of 1. The long term operation caused internal part of component wear out especially
    bushing bearing and impeller unbalance and than volute casing wear out.
    Trouble
    2. Wear out of the bearing bushing and than oil seal damage due to long term
    operation to oil contamination by water.

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    Countermeasure 1. Making shaft, balancing impeller and volute casing at third party.
    2. Restoring all the pump components by proper measures

    Future Plan 1. Purchasing the new pumps for block maintenance.


    2. Making shaft, balancing impeller and volute casing at third party..
    Remark Predective maintenece monitoring (statistical based and conditional based)

    Attachment 1. P&ID
    2. Inspection Results of Lube oil pump existing condition
    3. Trouble report of reclaim water pump A/B, based of Service Request Record
    2013/20014

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    1. P & ID

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    2. Inspection Results of Lube oil pump existing condition

    Part View

    bearing bushings DE #A

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    shaft bearing bushings

    bearing bushings NDE #A

    bearing bushings DE #B

    bearing bushings NDE #B

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    shaft mechanical seal #A


    shaft mechanical seal

    shaft mechanical seal #B

    shaft oil seal

    Oil seal DE #A

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    Oil seal NDE #A

    Oil seal DE #B

    Oil seal NDE #A

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601
    PT.KOMIPO PEMBANGKITAN JAWA Doc Ref. KPJB-0953-04
    BALI Form
    PLTU TANJUNG JATI B UNIT #3&4 KPJB-0953-04-ZZ-FM-01
    No.
    Design
    Trouble Inspection Report Division
    Mechanical Division
    Revision
    Laporan Inspeksi Gangguan 00
    Number

    Tanjung Jati B #3&4 Coal Fired Power Plant


    Desa Tubanan, Kecamatan Kembang, Kabupaten Jepara
    Jawa Tengah, Indonesia Tel. 0291 4270493 Fax. 0291 4270601

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