PERAWATAN, PERBAIKAN DAN INSTALASI

 
POMPA SENTRIFUGAL SEMBILAN TINGKAT

  Maintenance, Repair and Instalation of a

Nine Stages Centrifugal Pump
 

 
Laporan ini disusun untuk memenuhi salah satu syarat menyelesaikan pendidikan
  DIPLOMA III PROGRAM STUDI TEKNIK MESIN

  Di Jurusan Teknik Mesin

 

 
Oleh
Adam Dwipratama Hartanto
NIM : 151211033

POLITEKNIK NEGERI BANDUNG

2018
 

Scanned with CamScanner

 

Scanned with CamScanner

 

Setiap
  kesedihan maupun kesulitan yang datang, akan ada juga
  kesenangan dan kemudahan yang ikut bersamanya.
 DYA -
 
 i
 
ABSTRAK
 

 
Pompa Sentrifugal banyak digunakan sebagai mesin atau peralatan bantu
 
produksi di industri, diantaranya adalah industri pupuk kimia, tekstil, perminyakan,
 
pertambangan dan pembangkit. Pemahaman dan kompetensi tentang instalasi,
pemeliharaan
  dan pengujian kinerja pada sistem pompa sentrifugal dianggap
penting, salah satu kegiatan praktek perlu dilakukan untuk pemahaman dan
 
kompetensi mata kuliah Mesin Fluida, Perawatan Pompa dan Kompresor di
 
Laboratorium Fluida , Thermal dan Otomotif. Di laboratorium Fluida, Thermal dan
Otomotif
  terdapat pompa sentrifugal sembilan tingkat jenis end suction merk stork
yang
  memerlukan perbaikan dan instalasi. Pompa sentrifugal Sembilan tingkat akan
digunakan untuk pengujian kinerja pompa. Pelaksanaan perbaikan dimulai dengan
 
pengecekan awal, disassembly, pembersihan komponen pompa, inspeksi,
penggantian komponen bila diperlukan, assembly, instalasi dan pengujian operasi
pompa setelah dilakukan perbaikan.Pengujian operasi pompa dilakukan pada
bukaan katup penuh dan putaran 1455 Rpm. Setelah dilakukan perbaikan, pompa
sentrifugal sembilan tingkat merk Stork dan digunakan untuk pengujian kinerja
pompa. Pompa tersebut memiliki head maksimal 41,3183 mka, dan debit maksimal
0,00121 m3/s.

Kata Kunci : Pompa sentrifugal sembilan tingkat, Perawatan, Perbaikan, Instalasi,

Head, Debit

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 ii
 
ABSTRACT
 

 
Centrifugal pumps are widely used as a machine or auxiliary equipment in
 
industrial production, such as chemical fertilizer industrial, textile, petroleum, mine
 
workings and power plants. It is important to understanding and competence of the
installation,
  maintenance and performance testing on centrifugal pump system, on
the other hand practice is necessary for understanding and competency courses
 
Fluid Engineering and Maintenance Pumps and Compressors in laboratories Fluid,
 
Thermal and automotive. In the thermal, fluid, and automotive laboratory having a
centrifugal
  pump end suction. Nine stage that required repair and installation. The
nine
  stages centrifugal pump will be used for pump performance testing. The
implementation of the maintenance and repair was started with the initial
 
evaluation, disassembly, cleaning of pump components, inspection, replacement of
components when necessary, assembly, installation and testing of pump operation
after the repair. The operation test of pump was carried out at full valve opening and
at 1455 rpm. After the repair, the nine-centrifugal pump is used for pump
performance testing. Pump operation test it had maximum head 41.3183 mH2O at
0.00121 m3/s flow rate.

Keywords: Centrifugal pump nine levels, Maintenance, Repair, Installation

ii
 iii
 
KATA PENGANTAR
 

 
Puji dan syukur penulis panjatkan atas kehadirat Allah SWT, beserta junjungannya
 
Nabi Muhammad SAW. Karena berkat rahmat dan karunia-Nya penulis dapat
 
menyelesaikan penulisan Tugas Akhir ini.
  Penulis mengucapkan banyak terima kasih kepada semua pihak yang telah
  memberikan dukungan selama melaksanakan Tugas Akhir. Ucapan terima kasih
penulis sampaikan kepada:
 
1.   Orang tua penulis yang selalu mendukung secara moril dan materil kepada
penulis.
 
2. Bapak Drs. Parno Rahardjo, M.Pd., M.Sc., Ph.D., selaku Ketua Jurusan
  Teknik Mesin dan pembimbing satu;
3. Bapak Musyafak, ST., M.Eng., selaku Ketua Program Studi Teknik Mesin;
4. Bapak Prasetyo, ST., M.Eng., selaku pembimbing dua;
5. Bapak Achmad Hatta, B.Eng. M.Eng., selaku wali kelas;
6. Seluruh Dosen Jurusan Teknik Mesin;
7. Staf Jurusan Teknik Mesin;
8. Keluarga besar Himpunan Mahasiswa Mesin; dan
9. Semua pihak yang telah membantu dalam menyelesaikan laporan ini.

Penulis berharap laporan ini dapat bermanfaat bagi yang memerlukannya namun
dilain pihak bila laporan ini datang dengan segala kekurangan dan
ketidaksempurnaan, Penulis sangat mengharapkan masukan, kritik dan saran yang
bersifat membangun demi penyempurnaan laporan ini.
Bandung, Agustus 2018

Penulis

iii
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DAFTAR ISI
 

 
ABSTRAK .....................................................................................................................i
 
ABSTRACT ................................................................................................................. ii
 
KATA PENGANTAR ................................................................................................ iii
 
DAFTAR ISI................................................................................................................iv
 
DAFTAR GAMBAR................................................................................................. vii
 
DAFTAR TABEL .......................................................................................................ix
 
BAB I PENDAHULUAN ......................................................................................... I-1
 
1.1 Latar Belakang ....................................................................................... I-1
 
1.2 Perumusan Masalah ............................................................................... I-1
1.3 Tujuan ..................................................................................................... I-2
1.4 Ruang Lingkup ....................................................................................... I-2
1.5 Batasan masalah ..................................................................................... I-2
1.6 Sistematika Penulisan............................................................................. I-3

BAB II LANDASAN TEORI ..................................................................................II-1

2.1 Pompa Sentrifugal .................................................................................II-2
2.1.1 Pompa Sentrifugal Tipe Single Stage.......................................II-2
2.1.2 Pompa Sentrifugal Tipe Multistages ........................................II-2
2.1.3 Komponen Pompa Sentrifugal .................................................II-3
2.2 Gangguan pada Pompa Sentrifugal ......................................................II-5
2.2.1 Pemeriksaan pada pompa sentrifugal .......................................II-7
2.3 Pemeliharaan Pompa Sentrifugal ..........................................................II-7
2.3.1 Pengertian Pemeliharaan (Maintenance) .................................II-8
2.3.2 Pemeliharaan berkala pada pompa sentrifugal ......................II-11
2.4 Konstruksi dan Komponen Pompa Sentrifugal Sembilan Tingkat ....II-12
2.5 Instalasi Pompa Sentrifugal ................................................................II-13
2.5.1 Penempatan Pompa.................................................................II-13
2.5.2 Pondasi dan Kerangka ............................................................II-15
2.6 Pengelasan ...........................................................................................II-16
iv
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2.6.1 Klasifikasi Las Berdasarkan Sambungan dan Bentuk Alurnya.II-
  17
  2.7 Sistem Kelistrikan ...............................................................................II-18

  2.7.1 Motor Induksi .........................................................................II-19

2.7.2 Starter Star – Delta .................................................................II-19
 
2.8 Alat Ukur yang Digunakan .................................................................II-20
  2.9 Komponen Sistem Pemipaan ..............................................................II-23
  2.9.1 Pipa ..........................................................................................II-23

 
2.9.2 Jenis pipa berdasarkan kegunaannya .....................................II-23
2.9.3 Katup (Valve) ..........................................................................II-24
 
2.9.4 Fitting ......................................................................................II-27
  2.9.5 Flange (Flens) ........................................................................II-31
  BAB III METODE DAN PROSES PENYELESAIAN........................................ III-1
3.1 Diagram Alir Penyelesaian Masalah .................................................. III-1
3.2 Langkah Penyelesaian ......................................................................... III-2
3.2.1 Evaluasi awal .......................................................................... III-3
3.2.2 Disassembly ............................................................................ III-3
3.2.3 Cleaning .................................................................................. III-3
3.2.4 Evaluasi Komponen ................................................................ III-4
3.2.5 Assembly.................................................................................. III-4
3.2.6 Uji Operasi .............................................................................. III-4
3.3 Objek Pengujian .................................................................................. III-5
3.4 Instrumentasi ....................................................................................... III-7
3.5 Metode Pengujian................................................................................ III-8

BAB IV PERBAIKAN, PERAWATAN DAN INSTALASI POMPA

SENTRIFUGAL SEMBILAN TINGKAT ............................................. IV-1
4.1 Evaluasi Awal...................................................................................... IV-1
4.2 Proses Perbaikan Pompa Sentrifugal Sembilan Tingkat .................... IV-1
4.2.1 Disassembly pompa sentrifugal Sembilan tingkat ................. IV-1
4.2.2 Pembersihan pompa sentrifugal Sembilan tingkat ................ IV-2
4.2.3 Evaluasi Komponen................................................................ IV-3
4.2.4 Assembly Pompa Sentrifugal Sembilan Tingkat .................... IV-5

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4.3 Proses pembuatan instalasi pompa sentrifugal sembilan tingkat ....... IV-3
  4.3.1 Pembuatan rangka meja .......................................................... IV-3
  4.3.2 Pembuatan Landasan .............................................................. IV-4

  4.4 Komponen sistem pemipaan ............................................................... IV-5

4.4.1 Perhitungan NPSH .................................................................. IV-7
 
4.4.2 Langkah penguliran pipa ........................................................ IV-8
  4.4.3 Langkah pengelasan pipa ..................................................... IV-10
  4.5 Instalasi Pompa Sentrifugal Sembilan Tingkat ................................ IV-11

 
4.6 Uji Operasi......................................................................................... IV-14
4.6.1 Metode Uji Operasi............................................................... IV-14
 
4.6.2 Parameter Uji Operasi .......................................................... IV-14
  4.6.3 Hasil Uji Operasi .................................................................. IV-16
  4.6.4 Uji Kinerja............................................................................. IV-17
4.6.5 Komparasi Data .................................................................... IV-18

BAB V KESIMPULAN DAN SARAN ................................................................. V-1

5.1 Kesimpulan ........................................................................................... V-1
5.2 Saran ..................................................................................................... V-1

DAFTAR PUSTAKA .............................................................................................. V-2

vi
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DAFTAR GAMBAR
 

 
Gambar 2.1, Pompa sentrifugal tipe single stage closed couple (A) dan
  [2]
Pompa sentrifugal tipe single stage end suction (B) ................ II-2
 
Gambar 2.2 Pompa sentrifugal tipe multistages closed couple dan Pompa
  sentrifugal tipe multistages end suction ......................................... II-3
Gambar 2.3, Pompa sentrifugal [2] ........................................................................... II-3
 
Gambar 2.4, Maintenance Strategy [4] ..................................................................... II-8
 
Gambar 2.5, Konstruksi Pompa Sentrifugal ......................................................... II-12
Gambar
  2.6, Contoh instalasi pompa sentrifugal tipe multistages ....................... II-13
Gambar
  2.7 Letak tadah isap dan pompa [6] .......................................................... II-14

  Gambar 2.8 Jenis – jenis sambungan dasar........................................................... II-17

Gambar 2.9 Macam – macam sambungan T ........................................................ II-18
Gambar 2.10 Water meter ..................................................................................... II-20
Gambar 2.11 Bourdon Tube .................................................................................. II-21
Gambar 2.12 Bellows ............................................................................................. II-22
Gambar 2.14 Capsule Diafragma .......................................................................... II-23
[9]
Gambar 2.15, Gate valve ................................................................................... II-25
Gambar 2.16, Ball valve [9] .................................................................................... II-25
[10]
Gambar 2.17, Globe valve ................................................................................ II-26
[10]
Gambar 2.18, Check valve ............................................................................... II-26
[10]
Gambar 2.19, Butterfly valve ........................................................................... II-27
[10]
Gambar 2.20, Relief valve ................................................................................ II-27
[6]
Gambar 2.21, Elbow 90 dan 45 derajat regular dan long radius ...................... II-28
[6]
Gambar 2.22, Tee ............................................................................................... II-28
[6]
Gambar 2.23, concentric reducer dan excentric expander ............................... II-29
Gambar 2.24, Cap [11] ............................................................................................ II-29
[11]
Gambar 2.25 Lateral (Y-Bend) ........................................................................ II-29
Gambar 2.26, Cross [11] .......................................................................................... II-30
[11]
Gambar 2.27, Return bend ............................................................................... II-30

vii
 viii
 

Gambar 2.28, Union [6] .......................................................................................... II-31

  [6]
Gambar 2.29, Nipple .......................................................................................... II-31
 
Gambar 2.30, Slip on flange [7] .............................................................................. II-32
[7]
  Gambar 2.31, Socket welding flange ................................................................ II-32
Gambar
  2.32 Lap joint flange [7]............................................................................ II-33
[7]
Gambar
  2.33 Welding neck flange .................................................................... II-33

  Gambar 2.34 Blind flange [7].................................................................................. II-34

[7]
  Gambar 2.35 Threaded flange ........................................................................... II-34
Gambar 3.1, Diagram Alir Penyelesaian Masalah ................................................. III-1
 
Gambar 3.2, Pompa sentrifugal Sembilan tingkat Stork MCHZ dan Motor
  listrik MEZ / Siemens 132S04 ...................................................... III-5
  Gambar 3.3, Pressure Gauge ................................................................................. III-7
Gambar 3.4, Flow Meter......................................................................................... III-7
Gambar 3.5, Inverter ............................................................................................... III-8
Gambar 4.1, Disassembly Pompa Sentrifugal Sembilan Tingkat ........................ IV-2
Gambar 4.2, Hasil Pembersihan Komponen Pompa Sentrifugal Sembilan
Tingkat ........................................................................................... IV-3
Gambar 4.3, Pelumasan Komponen Pompa Sentrifugal Menggunakan Grease .. IV-5
Gambar 4.4, Pemasangan Impeller dan Pasak pada Setiap Stagenya ................... IV-2
Gambar 4.5, Peletakan Pompa dan Motor pada Landasan .................................... IV-2
Gambar 4.6 Proses Pemotongan Besi Profil L Menggunakan Gerinda Tangan... IV-3
Gambar 4.7 Hasil Pembuatan Rangka Meja .......................................................... IV-4
Gambar 4.8 Hasil Pembuatan Landasan Pompa dan Motor .................................. IV-5
Gambar 4.9, Proses Pemotongan Pipa ................................................................... IV-9
Gambar 4.10, Hasil Pemotongan dan Penguliran Pipa ........................................ IV-10
Gambar 4.11, Hasil Instalasi Pompa Sentrifugal Sembilan Tingkat ................... IV-13
Gambar 4.12, Kurva karakteristik head dengan debit ( H – Q) ........................... IV-17

viii
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DAFTAR TABEL
 

 
Tabel 2.1 Komponen pompa sentrifugal ............................................................... II-12
 
Tabel 3.1, Evaluasi Awal ........................................................................................ III-3
  3.2, Evaluasi Komponen .............................................................................. III-4
Tabel
  Tabel 3.3, Uji operasi .............................................................................................. III-5
Tabel 3.4, Spesifikasi Pompa sentrifugal Sembilan tingkat Stork MCHZ ........... III-6
 
Tabel 3.5, Spesifikasi motor listrik MEZ / Siemens 132S04 ................................ III-6
 
Tabel 4.1, Hasil Evaluasi Awal .............................................................................. IV-1
  4.2, Hasil evaluasi komponen pompa sentrifugal Sembilan tingkat ........... IV-3
Tabel
  Tabel 4.3, Parameter Uji Operasi ......................................................................... IV-14

ix
 
DAFTAR PUSTAKA
 

 
1. Sularso dan Haruo Tahara. (2006). Pompa dan Kompressor. Jakarta : Pradnya
 
Paramita
2.   http://www.lcthomsen.com/centrifugal-pumps ( diakses pada 19 Januari
  2017)
3. Raharjo, Parno. (2014). Teknik Pemeliharaan Mesin: Teknik Monitoring
 
Kondisi Mesin. Bandung: UPT Penerbit Politeknik Negeri Bandung.
 
4. Sudrajat, Ating, (2011). Pedoman Praktis Manajemen Perawatan Mesin
  Industri, Bandung : Refika Aditama

5.   Setiadi, 2014, Perbandingan Macam-macam Valve dan Fungsinya, Yogyakarta,

Institut Sains dan Teknologi AKPRIND Yogyakarta.
 
6. Teknik Perawatan Mekanik, 2014, Fitting dan Brancing, Bandung, Politeknik
Negeri Bandung.
7. Avtur, 2012, Flange, Batam.
8. Hicks, Tyler G. (1972). Pump Operation and Maintenance. New Delhi :
McGraw-Hill
9. Mobley, R. Keith. 2014. Maintenance Engineering Handbook, Eighth
Edition. Diambil dari:
https://www.accessengineeringlibrary.com/browse/maintenance-engineering-
handbook-eighth-edition (diakses pada 09 Desember 2017)
10. Standar Uji Pompa Sentrifugal SNI 0141.1-2008. Jakarta: Badan Standarisasi
Nasional
 

Adam Dwipratama. H
 

  M E C H A N I C A L E N G I N E E R I N G

  +62 821-3050-1907
adamdwipratama@hotmail.com
 
Jl. Diwangsa 1 No.3 Nusa Indah Residence
  Kecamatan Kota Bogor Utara
Kelurahan Tanah Baru, Kota Bogor
 
As a fresh graduate in majoring Mechanical Engineering, I have a vision that
  can work as a team and also individuals professionally for the realization of
high efficiency at work. In order to a realization that vision, I optimize my
values which are responsible, hardworking, and carefully at works. By
optimizing the value that I have, and the desire to keep learning. I am sure
can contribute to the success of the company.

PERSONAL INFORMATION

Date of Birth : 21st of March 1996

Place of Birth : Cirebon
Religion : Islam
Status : Single
IPK : 3.33

EDUCATION

2015 - 2018 Politeknik Negeri Bandung ( D3 - Teknik Mesin )

2011 - 2015  SMK N 1 Cimahi ( Industrial Instrumentation )

WORK EXPERIENCE

PT. TAKA PRECISION MANUFACTURING INDONESIA

Jl. Raya Cinunuk No.274, Cinunuk, Cileunyi, Bandung, Jawa Barat 40624

Agustus 2017 - September 2017

Position : on job training as maintenance technician
Working description :
 1. Repair and service rotating element, especially for turbin and centrifugal 
    pump
2. Dimentional Inspection
3. NDT ( UT and Liquid Penetrant Inspection)
4. Run Out Shaft 5. Shaft Straightening 6. Balancing Impeller
5. Dis - assembly and assembly centrifugal pump
 PT. TITIS SAMPURNA INSPECTION
  LPG Plant Limau Timur, Desa Kemang Tanduk Kec.Kapak Rembang
Tengah, Prabumulih, Sumatra Selatan. Indonesia

  Agustus 2014 - Desember 2014

Position : on job training as Instrumentation technician
  Working description :
1. Preventive Maintenance Industrial Generator
  2. Calibration control valve and valve positioner
3. Calibration and adjustment measuring instrumentation especially for :
      - Level
    - Pressure
      - Temperature
4. Installing measurement and control device 
 

  ORGANIZATION EXPERIENCE

Himpunan Mahasiswa Mesin Politeknik Negeri Bandung As member

 
Polytechnic Karting Team Bandung As Driver
Solidarity Music Mechafest - Decoration division As Team Leader
 

  ACHIEVMENT

English Profiency Certificate

Sertifikat Pelatihan Pembinaan Fisik dan Mental
Piagam Penghargaan Titis Sampurna 
English Testing and Training Center Certificate 
Sertifikat Komandan Pusat Pendidikan Perhubungan Kodiklat TNI
Angkatan Darat

SKILL

• Basic operation machine : lathe ( conventional and CNC Fanuc ), Milling

(conventional and CNC Fanuc), Scrup (conventional), Grinding
(conventional ), Drilling machine, and Bending machine
 
Welding    :  SMAW (Shielded Metal Arc Welding), GMAW (Gas Metal Arc
Welding), GTAW (Gas Tungsten Arc Welding), and OAW (Oxy Acetylene
Welding)

Software    : Microsoft Office, Microsoft Excel, Microsoft Power Point, Catia

V5 R19, AutoCad, and Festo Fluidsim

Programming    : G-code

Familiar with P&ID (Piping and Instrument Diagram )

Familiar with Instrumentation Equipment (sensing element, Transmitter,

Control Valve, Positioner, Transducer, etc)

English skill ( Speaking : Pasive, Reading : Active, Writing : Active )