Nama : Naufal Nibrosul M

Kelas : OM 2

Proyeksi Jabatan : Officer Rencana dan Evaluasi Operasi PLTU Jeranjang (Lombok)

Predictive Maintenance pada Feed Water Pump Menggunakan

Vibration Analysis

Pusat Listrik tenaga uap (PLTU) Jeranjang menggunakan boiler tipe circulating
fluidized bed (CFB) yang biasa digunakan pada pembangkit dengan kapasitas
sedang/medium. Prinsip kerja boiler CFB yaitu terdapat material antara yang berperan
sebagai penghantar panas. Pada umumnya, material yang digunakan berupa pasir dengan
jenis kwarsa yang terstandarisasi, pasir tersebut akan berputar-putar di dalam furnace.
Langkah yang dilakukan sebelum fluida memasuki boiler, yaitu fluida (air) akan dipompakan
dari deaerator menuju economizer oleh feed water pump. Komponen feed water pump
merupakan komponen yang penting karena jika komponen tersebut rusak, akan berdampak
pada debit air yang dapat dipompakan ke economizer, yang pada akhirnya mempengaruhi
efisiensi thermal dari boiler. Oleh karena itu, pada artikel ini, saya akan mengambil studi kasus
tentang predictive maintenance pada komponen feed water pump di PLTU Pangkalan Susu
menggunakan metode vibration analysis.

Resume Artikel

A. Boiler Feed Water Pump

Boiler feed water pump merupakan salah satu aplikasi jenis pompa sentrifugal pada
industry, komponen ini memiliki peran penting sebagai pemasok fluida pada boiler. Fungsi
utama FWP untuk mengontrol debit fluida dari water tank menuju boiler dengan tekanan
tertentu. Misalnya, ketika pembangkit beroperasi dengan beban maksimal, FWD akan
menambah debit air yang masuk ke dalam boiler untuk memenuhi kebutuhan beban tersebut.
Feed water pump memiliki dua komponen utama, yaitu pompa dan motor elektrik yang saling
dikopel. Pompa yang digunakan menggunakan mechanical seal, thrust, dan sleeve bearings.

Salah satu failure yang sering terjadi pada bagian feed water pump adalah shaft
misalignment yang disambungkan dengan sistem kopel, sehingga berdampak terjadinya
vibrasi yang dapat merusak komponen. Untuk itu, perlu dilakukan maintenance untuk
mempertahankan keandalan komponen dan memperpanjang masa pakai komponen tersebut.
Salah satunya dapat dilakukan dengan predictive maintenance, yang berfokus pada direct
monitoring pada objek/komponen tertentu. Dengan menggunakan sensor vibrasi, akan
didapatkan karakter sinyal khusus yang tergambar pada vibrometer, gambaran sinyal tersebut
akan dianalisis sehingga dapat ditentukan jenis misalignment, yaitu dapat berupa parallel
misalignment atau angular misalignment.

B. Maintenance

Maintenance merupakan suatu aksi yang dilakukan untuk menjaga keandalan suatu alat,
agar tetap dalam kondisi yang baik dan memiliki masa pakai yang lebih panjang. Beberapa
tugas pada bagian maintenance adalah sebagai berikut:

1. Melakukan pengawasan failure pada alat

2. Berkoordinasi pihak lain, ditakutkan aka ada panitia di sini
3. Melakukan efisiensi terkait biaya operasional
4. Melakukan pengawasan terkait efisiensi thermal dari turbin yang sedang berjalan
5. Fokus pada tugas yang telah ditetapkan oleh perencana

Terdapat 3 jenis tahapan failure, yaitu early failures, useful life, wear out.

C. Metode

Metode yang dilakukan berupa pengumpulan data primer dan sekunder. Data primer
berupa pengumpulan informasi melalui interview, sedangkan data sekunder didapatkan dari
data historis Perusahaan. Tujuannya untuk mengetahui beberapa hal sebagai berikut:

1) Implementasi pemeliharaan pada boiler feed water pump pada PLTU Pangkalan Susu
2) Bagaimana cara melakukan pemeliharaan pada alat tertentu
3) Mengambil data menggunakan vibration tool
D. Analisis

Pengambilan data vibrasi menggunakan aplikasi VibXpert vibration tool, dengan skema
sebagai berikut:
 Gambar 1. 1. Step menggunakan ViXpert

Berdasarkan data historis di PLTU Pangkalan SUSU, pengukuran terakhir dengan

vibration tool menunjukkan kecepatan feed water pump sebesar 4,04 mm/s. Nilai tersebut
belum memenuhi alarm limit di antara 0 – 7,1 mm/s. Meskipun kecepatan belum menyentuh
tahap alarm, tetapi perlu adanya perbaikan untuk mengurangi risiko kecelakaan.

E. Kesimpulan

Analisis kegagalan pada boiler feed water pump dapat dilakukan dengan metode
predictive maintenance, tools yang dapat digunakan secara efektif yaitu vibration analysis.
Sebagai studi kasus, pada PLTU Pangkalan Susu, memiliki level kecepatan 3X dari total
kecepatan sebesar 4,04 mm/s, sehingga dapat disimpulkan kegagalan yang terjadi adalah
misalignment. Sebagai saran, untuk analisis selanjutnya, bisa ditambahkan dengan
pengecekan lubrikasi, fricrion, dan wear, sehingga maintenance yang dilakukan dapat lebih
efektif.

Karena pusat listrik tenaga uap di Pangkalan Susu masih memiliki kemiripan dengan
PLTU Jeranjang. Oleh karena itu, teknologi untuk melakukan predictive maintenance yang
ada di Pangkalan Susu kemungkinan dapat pula ditempatkan pada PLTU Jeranjang.
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JURNAL INFOKUM, Volume 10, No.3, Agustus 2022 ISSN : 2302-9706

PREDICTIVE MAINTENANCE ON FEED WATER PUMP AT

PANGKALAN SUSU ELECTRIC STEAM POWER PLANT (PLTU)

Govin Hasiando Marpaung1, Siti Anisa2, Solly Aryza3

Electrical Engineering, Pembangunan Panca Budi University

Jl. Gatot Subroto km 4,5, Sei Sikambing , Medan 20122, North Sumatera
gopin.hanz@gmail.com1;sitianisah@dosen.pancabudi.ac.id2;sollyaryzalubis@gmail.com3

ABSTRACT
Article Info Maintenance is an activity to keep the machine/production equipment, and make
Received, 01/08/22 repairs or replacements to increase production in the industrial world. There are
several types of maintenance developed, namely Preventive maintenance, corrective
Revised,28/08/22
maintenance, and predictive maintenance. Maintenance techniques on direct object
Accepted. 30/08/22
measurement monitoring are more applied to the industrial world because it is done
without stopping operation on a machine, this treatment technique is also called
predictive treatment, and requires analysis to monitor engine conditions, such as the
measurement of vibration signals. Each vibration signal generated has different
damage. Misalignment is one type of damage caused by the frequent vibration of the
shaft and clutch. The vibration signal generated by misalignment has its own
characteristic seen in the vibration spectrum. In this undergraduate task will be
analyzed angular misalignment vibration signal at feed water pump by taking data at
horizontal drive point. The vibration signal at the feed water pump generates angular
misalignment through the 3X rpm spectrum where the first rpm is larger than the
next two rpm. From the measurement of vibration, it can be seen through the
comparison of vibration value to trending with the prevailing standard showing high
amplitudes on the horizontal motor drive of 2.65 mm/s based on ISO 10816- 3
standard.
Keywords: maintenance, vibration analysis, vibration, spectrum, misalignment

1. INTRODUCTION
In response to the growing demand for electricity consumption in Indonesia, especially in
North Sumatra, PT PLN (PERSERO) has built a coal-fired power plant. The presence of this thermal
power plant will help the country's electricity supply, especially in Sumatra. Steam power plants are
known to be plants with high potential for equipment damage, especially in the balance-of-plant
(BOP) area. Therefore, damage can be prevented by using appropriate systems and methods.
Common damage that occurs to motors and pumps is well known as shaft misalignment, or
misalignment between the driver and the driven vehicle. Misalignment occurs on shafts that are
connected by couplings. This damage can result in excessive vibration, which can damage engine
components and further shorten the life of the engine. The vibration signal caused by misalignment
has its own characteristics found in the resulting vibration spectrum. The vibration spectrum can
indicate the type of misalignment that occurs, i.e., parallel misalignment or angular misalignment with
unique characteristics. Of course, the resulting vibration spectrum is not just misalignment, as it can
be affected by other damage such as imbalance, cavitation, bearing failure, or mechanical loosening.
If the characteristics of the vibration are not known, it is very difficult to determine the source of the
vibration through vibration spectrum analysis. Maintenance is the activity of maintaining and
servicing equipment, machinery, and production facilities, and making repairs and replacements
necessary to achieve planned production operating conditions.
This maintenance process minimizes sudden equipment shutdowns and can halt production
processes in industries where production processes are ongoing. The maintenance techniques
developed are based on direct monitoring of the measured object or better known as predictive
maintenance. This maintenance process requires the diagnosis and analysis of the measuring object.
There are several media used to monitor the condition of a machine, such as the measurement of
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vibration signals. Vibration signal measurements are typically used to monitor the condition of
rotating machinery such as motors and pumps. Vibration signals displayed on a vibrometer are
indicated by defects or damage that have occurred in the machine. Diagnosis of this damage is
performed for the shutdown schedule repair process.
Mean Time Between Failures (MTTF) is the average time interval between the time a
machine or component is repaired and the damage that occurs before the machine or component is
damaged again. Mean time to repair (MTTR) is the average time to make the necessary repairs to a
component (Kurniawan, 2013). An Age replacement method is a replacement action performed when
an operation reaches a certain predetermined age. Even if no damage has occurred in a certain time
interval, replacement is performed as a precautionary measure. If the system is damaged in a certain
time interval, the following replacement and repair actions are performed based on calculations from
the time of repair replacement.

2. Literature Review.
2.1. Multifuel Boiler
According to Djokosetyardjo (2003), a boiler or steam boiler is a closed container in which
the heat of combustion is conducted in water until hot water or steam is formed. Hot water or steam at
a specific pressure is then used to transfer heat to a process. Water is a useful and inexpensive
medium for transferring heat to a process. When water is boiled until it becomes steam, its volume
increases 1,600 times, producing a force similar to explosive gunpowder. The boiler is therefore a
device that must be very well managed and maintained. In the energy conversion process, the boiler
has the task of converting the chemical energy stored in the fuel into heat energy that is transferred to
the working fluid.
The boiler is used in PT. Toba Pulp Lestari, Tbk, there are 2, namely multi-fuel boiler and
recovery boiler. The multi-fuel boiler uses fiber fuel, palm shells, and bark, while the recovery boiler
uses waste fuel from pulp processing. The boiler we will be studying is the multi-fuel boiler.
The boiler system consists of a feedwater system, a steam system, and a fuel system. The feedwater
system automatically supplies the boiler with water, depending on the steam demand. Various water
taps are provided for maintenance and repair purposes. The steam system collects and controls steam
production in the boiler. The steam flows through the piping system to the point of consumption.
Throughout the system, the steam pressure is controlled by a water tap and monitored by a pressure
switch. The fuel system is all the equipment used to provide the fuel to produce the required heat. The
equipment required for the fuel system depends on the type of fuel used in the system. The water
supplied to the boiler for conversion to steam is called feed water. The two sources of feed water are:
1. condensate or condensed steam that returns to the process.
2. make-up water (treated raw water), which must be fed into the process plant from outside the
boiler room.

2.2. Boiler Feedwater Pump

The boiler feedwater pump is a very important engine component in a multi-fuel boiler. The
boiler feedwater pump is one of the applications for the use of large centrifugal pumps in the industry.
The purpose of this pump is to control a certain amount of water from the water tank (feed water tank)
and deliver it to the boiler at a certain pressure. Before the water enters the boiler, it is usually
preheated.
A boiler feedwater pump (BFWP) consists of a pump and a drive. The drive is an electric motor
directly coupled to the pump with coupling as a link between the two. This pump has a single flow
with multistage pumping characteristics. This pump also uses a mechanical seal and thrust and sleeve
bearings.

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Figure 1. How the Feedwater Pump Works

BFWP supplies a certain amount of water to the boiler, which in practice varies the amount of
water required by that boiler. The change is based on the amount of steam from the boiler product
needed for the next process. For example, in a steam power plant, if the electrical load is high, the
demand for steam entering the steam turbine is also high. Thus, automatically the amount of water
entering the boiler is also high. And vice versa when the electrical load is low.

2.3. Maintenance Definition

Maintenance is a combination of various actions taken to keep an item in good repair or to bring
it to an acceptable condition. In past and present maintenance practice, maintenance can be defined as
the act of servicing a machine or factory equipment by extending the life of a machine or equipment.
Machines are often disputed between the maintenance and production departments. This is because
the maintenance department is considered a waste of money, while the production department
believes that it causes damage but also brings in money (Soemarno, 2008). In general, a product
manufactured by human cannot be damaged, but its useful life can be extended by repairs, which are
called maintenance (Corder, Antony, K Hadi, 1992). Therefore, maintenance activities are required,
which include the maintenance of machines used in the production process.
Performing maintenance on work equipment is said to bring benefits to companies operating in
the construction sector. According to Assauri (2004: 95), the objectives of maintenance are:
1. Maintaining the ability of tools or equipment to meet needs in accordance with production
goals or plans.
2. To ensure that the quality of the product/construction work meets the expected level in order
to meet the requirements of the product itself and to ensure that production activities are not
disrupted.
3. Reduce consumption and irregularities outside the limits and maintain the capital invested in
the company for a certain period in accordance with company policy.
4. Achieving the lowest possible level of costs through an effective and efficient performance of
maintenance activities as a whole.
5. Pay attention to and avoid operating activities that may jeopardize occupational safety.
6. Work closely with other major functions of an organization to achieve the organization's
primary objective of achieving the best possible return on profit or investment at a low total
cost.

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This type of maintenance is similar to predictive maintenance but is not regularly scheduled.
Predictive maintenance anticipates the failure of a piece of equipment before a total failure occurs.
Predictive maintenance analyzes the condition of a piece of equipment based on the trend of
equipment behavior.

This trend can be used to predict how long the equipment can continue to operate normally.
Preventive maintenance is a scheduled and planned maintenance activity. It is performed to anticipate
problems that may cause damage to components or equipment and keep them normal during
operation. Predictive maintenance techniques are very similar to medical diagnostics. Whenever the
human body has a problem, it shows signs or symptoms. The nervous system that provides this
information is the actual detection. Also, if necessary, a pathological test is performed to diagnose the
problem.

Figure 2. Predictive Analysis Diagram

Two shafts connected by a coupling can get into a condition where the axis between the two
shafts is out of alignment; this condition is called unbalance. Just like unbalance, misalignment is the
main cause of motor vibration. Some machines are equipped with flexible bearings and couplings that
can cause slight misalignment. However, it is uncommon to experience severe vibration due to
misalignment. The resulting forces and vibrations increase as misalignment increases. In a pump unit,
misalignment often occurs at the connection (coupling) between the drive shaft and the impeller shaft.
Just as with unbalance, the symptoms of misalignment can be easily observed in the frequency range
of the vibrations. The vibration frequency is usually 1x rpm, but in the case of a large misalignment,
the vibration frequency may be 2x or 3x rpm (Nicholas, 2000).

3. METHODS
Collecting data in the form of primary data and secondary data. For primary data, this is done
by interview. For secondary data, data collection is done by collecting company documents. Primary
data was collected through free interviews, with the aim of learning:
1. Implementation of boiler feed pump water maintenance and repair at PLTU Pangkalan Susu.
2. How the care and maintenance of the machine are handled.
3. Carrying out tests with a vibration tool.
The following is a research flow chart that requires the stages in the research process carried out in the
field.

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Figure 3. Research Flowchart

4. Analysis
The preventive maintenance discussed in this chapter is the measurement of vibrations on the
water machine of the feed pump. Predictive maintenance application to the feedwater pump is done
by measuring vibrations at the radial (vertical and horizontal) and axial points.

Figure 4. Vertical Vibration Measurement

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Figure 5. Axial Vibration Measurement

Measurements using the VibXpert vibration tool. The following are the steps to perform a vibration
test on the feedwater pump machine in the boiler at the Pangkalan Susu PLTU.

Figure 6. Steps to Use VibXpert

Based on data obtained by the author from the Pangkalan Susu PLTU, the last vibration
measurement on 27/01/2022 measured a velocity of 4.04 mm/s (ISO 10816-3/B), which was elevated
due to sound anomalies prior to the measurement.
The increase in the last vibration measurement of 4.04 mm/s did not exceed the established
alarm limit of 0 - 7.1 mm/s. Although the alarm limit was not reached, the increase indicates that the
vibration level in the feed pump water is indicative of damage. To analyze the damage, we can read
through the spectrum after measuring the last feed water.
In reviewing and analyzing the vibrations, we look for the cause of the vibrations. In the
analysis, there are two basic things that must be known, namely the source (source of the problem).
The source is the main cause of the vibrations and the severity, which is the consequences that result
from the source of the problem.
The main causes of vibration and the resulting equipment problems are as follows.
1. Unbalance
2. Misalignment
3. Looseness
4. Bent shaft
5. Damage to the rolling bearing
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Figure 7. Spectrum misalignment

Figure 7 shows the total vibration value of the BFWP on the vertical side of 4.04mm/s (ISO10816-
3A) at 3X Rpm. Vibrations in the vertical direction with a calculation of 3X Rpm indicate that the
BFWP has a misalignment in the coupling between the motor and the gearbox. To determine the type
of system damage based on the frequency spectrum, you can use the reference in the vibration
analysis table above.

CONCLUSIONS
The conclusion is after studying vibration measurements on the boiler feedwater pump
machine at PT. PLTU Pangkalan Susu are as follows The maintenance of the boiler feed water pump
is done by predictive maintenance with vibration monitoring, After analyzing the vibration spectrum
of the boiler feed pump with the occurrence of a speed level of 3X with a total value of 4.04 mm/s, it
can be concluded that the nature of the damage leads to misalignment, In the future, do not just do
vibration measurements. For example, also check lubrication, friction, and wear, Carry out planned
maintenance so that the machine can work effectively.

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