INCOMING INSPECTION REPORT
Subject REPAIR ROTOR GA 101
Customer PT. Petrokimia Gresik
Plant / Vessel Petrokimia Plant (Unit Urea Pabrik 1 -A)
Location Workshop PT. Goltens Jakarta
Customer Contact Bapak Dony / 0812-1293-0806
Authorized by PT. Goltens Jakarta
Engineers Soenarno
Goltens Job No 14-0131-23-068
Reported Date 5 April 2023
Pump Specification
MANUFACTURE Ebara Corporation ltd
SERIAL RM17930-01
MODEL 3X8 3/4 - 10 Stg HSB
SERVICE Ammonia Feed Pump
HEAD 2644 Mt
SPEED 6300 Rpm (Rpm)
CAPACITY 53 m3/h (Normal) / 62m3/h (Rated)
Reporting by : Acknowledge by :
Fachri Fani Suroso Rifan Abdul
Supervisor Workshop & Engine Manager Workshop & Engine
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
Job carried out Visual Repair Rotor GA 101
1 Visual Inspection
- Cleaning
- Check dimension shaft impeller pump
- Run out shaft impeller pump
- Check clearance wire ring to impeller pump
- NDT
- Report Inspection
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
Visual Inspection
1. Impeller No. 1
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.53 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.40 mm
- Scratches on outer impeller area
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
2. Impeller No. 2
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.57 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.42 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
3. Impeller No. 3
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.53 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.42 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
4. Impeller No. 4
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.42 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.63 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
5. Impeller No. 5
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing eye = 0.46 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
6. Side stage piece center (split)
Finding :
- Heavy rubbing on the stage piece center (split) area
Recommendation :
- Clean up all surfaces, and do inspection
- Build up on stage pieces
- Do polishing so that the surface roughness is max 0.4 micron Ra
- Check dimensions, clearance and adjust clearance values with OEM standard
- Perform mechanical run out measurements with a max value of 25 micron
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
7. Impeller No. 6
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing = 0.51 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing eye = 0.43 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
8. Impeller No. 7
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.47 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.41 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
9. Impeller No. 8
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.59 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.42 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
10. Impeller No. 9
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.60 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- The condition of the wearing casing on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.44 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
11. Impeller No. 10
Finding :
- Condition of wearing impeller side of eye destructive rubbing
- Condition of wearing casing eye destructive rubbing side
- Measurement clearance between wearing eye = 0.42 mm
- Impeller wearing condition on the destructive rubbing side of the hub
- Measurement clearance between wearing hub = 0.42 mm
Recommendation :
- Cleaning and visual inspection
- Measurement of mechanical run out with a max value of 25 micron
12. Shaft Outboard (NDE) nut - shaft sleeve
Finding :
- Light rubbing & corrosion on the journal shaft
Recommendation :
- Clean up all surfaces of the journal shaft.
- Perform NDT on the surface of the journal shaft after cleaning up.
- Do polishing so that surface roughness max = 0.4 micron Ra
- Perform dimensional & mechanical run out measurements with a max value of 25 micron
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
13. Gland Seal & Balance piston
Finding :
- Light rubbing & corrosion on the journal shaft
Recommendation :
- Clean up all surfaces of the journal shaft.
- Perform NDT on the surface of the journal shaft after cleaning up.
- Do polishing so that surface roughness max = 0.4 micron Ra
- Perform dimensional & mechanical run out measurements with a max value of 25 micron
14. Gland Seal DE
Finding :
- Heavy rubbing & medium corrosion on Gland Seal
Recommendation :
- Clean up all surfaces.
- Build up on Gland Seal until the dimensions match the drawing.
- Perform NDT on the Gland Seal surface after clean up.
- Do polishing so that the surface roughness is max 0.4 micron Ra.
- Perform dimensional & mechanical run out measurements with a max value of 25 micron
15. Shaft Inboard (DE) nut - shaft sleeve
Finding :
- Light rubbing & light corrosion on the Journal Shaft inboard (DE)
Recommendation :
- Clean up all surfaces of the Journal Shaft.
- Perform NDT on the surface of the Journal Shaft after clean up.
- Do polishing so that the surface roughness is max 0.4 micron Ra.
- Perform dimensional & mechanical run out measurements with a max value of 25 micron
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
RECOMMENDATION
1. Metal spray shaft impeller on the scratch area, with hardness according to the original
material, Roughness 0.4 Ra. Finishing grinding
a) Side stage piece center (split)
b) Gland Seal DE
2. Individual balancing shaft impeller 1 to impeller 10 standard ISO 1940/1 G 2.5
3. Final Dynamic rotor balancing, standard ISO 1940/1 G 2.5
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
LIQUID PENETRANT
LIQUID PENETRANT EXAMINATION REPORT (Rotor GA 101)/Before
Job No : 14-0131-23-068 Customer : PT. Petrokimia Gresik
Pump Type : Ebara Date : 5 April 2023
Plant name : Petrokimia Plant (Unit Urea Pabrik 1 -A)
Item No : Ma teri al : Cast Iron SOP No : ASME V
Line/DWG No : Temp : AMBIENT Cri terion : ASME VIII
Surfa ce Prepa ration : As Welder As Rol led AS - Forged
Gri ndi ng Ma chi ni ng AS - Ca st Vi sua l
Sta ge of Exa mi na tion : Before / After PWHT Before / After Hydrotest
Technique
Col or Contra st Fluorescent Wa ter Wa sha bl e Sol vent Removal
Ma terial Product Ma nufa cturer Dwel l Time
Cleaner : SKC -S MAGNAFLUX
Penetrant : SKL - SP2 MAGNAFLUX Penetrant : 10 Mi nutes
Devel oper : SKD - S2 MAGNAFLUX Devel oper : 10 Mi nutes
Penetrant Appl i cation
Bla ck Light Intens ity :
Sprayi ng Brushi ng Light Intensity :
Light Meter :
Size Resul t Notes :
Part of Weld Wel d Di a
Sta mp Rounded Linea r ACC Ref NDT Penetrant rotor GA 101, Result No Cra ck
OK
OK
EXECUTOR
Hari
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
CLEARANCE WIRE RING TO IMPELLER
Job No : 14-0131-23-068 Customer : PT. Petrokimia Gresik
Engine Type : Ebara Corporation ltd RM17930-01 Date : 4 April 2023
Vessel name : Petrokimia Plant (Unit Urea Pabrik 1 -A)
Position A B C D E F G H I J K
Impeller (OD) 127,85 107,95 127,90 107,95 127,77 107,93 127,77 107,93 127,95 107,93 107,93
Wearing (ID)
Act. Clearance 0,51 0,43 0,47 0,41 0,59 0,42 0,60 0,44 0,42 NA NA
Crearance Min. 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38
Design Max 0,76 0,80 0,76 0,80 0,76 0,80 0,76 0,80 0,76 0,80 0,80
Remark
Position L M N O P Q R S T U
Impeller (OD) 127,93 107,95 127,72 107,93 127,82 107,95 127,81 107,95 127,84 107,94
Wearing (ID)
Act. Clearance 0,46 0,42 0,63 0,42 0,53 0,42 0,57 0,40 0,53 NA
Crearance Min. 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38 0,35-0,38
Design Max 0,76 0,80 0,76 0,80 0,76 0,80 0,76 0,80 0,76 0,76
Remark
The target diameter for the outer wearing impeller diameter on the eye side has a range of 127.92 - 127.94 mm, while the targeted
outer diameter of the wearing impeller on the hub side has a range of 107.92 - 107.95 mm
Yellow highlight is under target dimensional
Reported by Approved by
Fachri Fani
PT. Goltens Jakarta
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
RUN OUT ROTOR
Job No : 14-0131-23-068 Customer : PT. Petrokimia Gresik
Engine Type : Ebara Corporation ltd RM17930-01 Date : 4 Maret 2023
Vessel name : Petrokimia Plant (Unit Urea Pabrik 1 -A)
Run out Radial
Position A B C D E F G H I J K L M
0⁰ 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00
90⁰ 0,00 0,00 0,00 0,00 0,00 0,01 0,01 0,01 0,01 0,01 0,02 0,02 0,02
180⁰ 0,00 0,01 0,01 0,01 0,01 0,02 0,00 0,00 0,00 0,00 0,01 0,01 0,01
270⁰ 0,00 0,01 0,01 0,01 0,01 0,00 0,02 0,04 0,04 0,02 0,05 0,05 0,00
Remarks OK OK OK OK OK OK OK OK OK OK OK OK OK
Position N OK P Q R S T U V W X Y
0⁰ 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00
90⁰ 0,00 0,00 0,00 0,00 0,00 0,01 0,01 0,01 0,01 0,01 0,00 0,00
180⁰ 0,00 0,01 0,01 0,01 0,01 0,02 0,00 0,00 0,00 0,00 0,00 0,00
270⁰ 0,00 0,01 0,01 0,01 0,01 0,00 0,02 0,04 0,04 0,02 0,00 0,00
Remarks OK OK OK OK OK OK OK OK OK OK OK OK
Run out Axial
Position A B C D E F G H I J K L M
0⁰ 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00
90⁰ 0,00 0,00 0,00 0,01 0,01 0,01 0,01 0,01 0,02 0,01 0,01
180⁰ 0,01 0,01 0,01 0,02 0,00 0,00 0,00 0,00 0,01 0,01 0,01
270⁰ 0,01 0,01 0,01 0,00 0,02 0,01 0,01 0,02 0,01 0,01 0,00
Remarks OK OK OK OK OK OK OK OK OK OK OK
Position N OK P Q R S T U V W
0⁰ 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00
90⁰ 0,00 0,00 0,00 0,00 0,00 0,01 0,01 0,01 0,01 0,01
180⁰ 0,00 0,01 0,01 0,01 0,01 0,02 0,00 0,00 0,00 0,00
270⁰ 0,00 0,01 0,01 0,01 0,01 0,00 0,02 0,02 0,02 0,02
Remarks OK OK OK OK OK OK OK OK OK OK
The run out value for the wearing & shaft area is max 25 micron, while the axial run out for the impeller side is max 13 micron.
Reported by Approved by
PT. Goltens Jakarta
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
DIMENSION SHAFT ROTOR
Job No : 14-0131-23-068 Customer : PT. Petrokimia Gresik
Engine Type : Ebara Corporation ltd RM17930-01 Date : 4 April 2023
Vessel name : Petrokimia Plant (Unit Urea Pabrik 1 -A)
BEFORE
A B C D E F G H I
0⁰ 64,95 67,84 69,81 79,90 107,60 107,70 107,33 79,90 69,83
90⁰ 64,95 67,84 69,81 79,90 107,60 107,70 107,33 79,90 69,83
J K L M N O
0⁰ 67,80 64,95 53,96 42,25 38,06 107,60
90⁰ 67,80 64,95 53,96 42,25 38,06 107,60
Reported by Approved by
Fachri Fani
PT. Goltens Jakarta
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]
Photo Documentation
Visual Inspection and Cleaning
Run out shaft Impeller, Result attached
Measurement clearance between wearing
Check Dimension shaft impeller pump, Result attached
[Link] Sunter Barat Blok AI/I, Sunter Agung - Jakarta Utara – 14350 Indonesia
Tlp :( 62)-(21)6408091, 6401150(Hunting), Fax :( 62)-(21)6519517
E-mail: jakarta@[Link] Website: [Link]