Penjelasan

Pe-milih-an
Pe-masang-an
Peng-operasi-an
Pompa Centrifugal
POMPA GEDUNG KOMERSIAL
Step by Step Pemilihan Pompa
Pemilihan pompa Centrifugal berdasarkan design/bentuk dan instalasi pipa :
Submersible, Horizontal end suction, vertical In line single stage, Multi stage,
booster pump dan lain sebagai nya.

Inline single-
Horizontal norm pump long-Vertical inline Submersible
stage Submersible sewage/drainage Horizontal Split Case
coupled multistage pump multistage pump
TP range range
NK and NKG range CR range SP range
LS range

 Best Efficiency +  Competive price +  Lower LCC

Step by Step Seleksi Pompa
New Pump atau instalasi baru, data data yang di butuhkan adalah :
1. Flow dalam satuan : m3/h, L/s, US Gpm, m3/s atau L/m
2. Head/Pressure dalam satuan : Bar, kg/cm2, kPa, Feet, PSI, atau m.
3. Design/bentuk pompa digunakan untuk apa ?
 End suction, Vertical Multistage/Single Stage, Double Suction/Split Case, Booster, Submersible
sewage/drainage dll.
 Aplikasi/peruntukan : HVAC, Booster/Transfer. Sewage/Drainage, Sirkulasi, Boiler, WTP/RO,
 Kebutuhan Rumah tangga : Jet Pump, Deep well, transfer, dan booster
4. Pemilihan secara manual menggunakan catalogue produk yang sesuai atau
menggunakan “SELECTION SOFTWARE”
5. Pilih pompanya, sesuai kriteria :
 Best Efficiency +  Competive price +  Lower LCC
 Step by Step Pemilihan Pompa
Replacement pumps, maka diperlukan data tambahan sebagai berikut:
1. Data pompa + motor terpasang,
 Data listrik : Power P1 or P2 kW, Flow m3/h, Head m, Pump Model Number, Manufacturer dll.
 Design/bentuk pompa, suction/discharge diameter, Flange standard DIN/JIS/ISO/ANSI.
 Operasianal pompa : running hours/year, atau tahun di pasang/umur dan kondisi/histori.
2. Pemilihan secara manual menggunakan catalogue produk yang sesuai
atau menggunakan “SELECTION SOFTWARE”
3. Seleksi pompa berdasarkan kriteria :
 Best Efficiency +  Competive price +  Lower LCC
 Step by Step seleksi Pompa
Contoh seleksi pompa
NBG 200-150-400/394 NBG 250-200-450/391
51
51 m
m
51 m

NOL NOL

Rated power - P2 90 kW Eta pump 85.0 % Rated power - P2 90 kW Eta pump 81.7 %

493 m3/h
493 m3/h
90 kW 90 kW
74 kW
79 kW
 PEMILIHAN MOTOR
POMPA
NKG 50-32-200/219 c/w MOTOR 15 kW  CR 15-4 c/w MOTOR 5.5 kW 

60 m
Q .H
= g.
u l ic =
60 m

ra P3 P2 P1
Hyd
P
P4=

15 m3/h 15 m3/h 5.5 kW

15 kW

Flow = 15 m3/h
Head = 50 m
Step by Step Pemilihan Pompa
Pilih kW Motor yang sesuai dengan
kebutuhan, pemilihan motor di pilih
berdasarkan pada NOL (non Over Load
Load) motor atau sesuai ketentuan ISO
5199, disini kita sebut sebagai P2 (kW
pompa), setelah itu sesuaikan power
motor P2 tersebut dengan range product
motor yang tersedia di market (jika
memang supplier/pabrikan hanya
menyediakan pompa “bare pumps”
saja.
 Motor Class
Pompa modern saat ini dibuat, sudah memiliki
Efficiency
tingkatan standarisasi motor class efficiency.
classification will be identified in several different
rating scales:-
IE4 – soon to be implemented
21
IE3
IE2
Premium EFF1
EFF2
Standard
No Class

Friday, December 23, 2022 9

Perbandingan Life Cycle Cost
…?
•C = initial cost, purchase price
ic

•Cin = installation and commissioning

•Ce = energy costs
•Co = operating costs LCC   Cic..d
•Cm = maintenance costs
•Cs = down time costs
•Cenv = environmental costs
•Cd = decommissioning and disposal

Evaluasi biasanya period 10 - 15 years

 85%
LCC   Cic..d

LCC = Cic + Ce + Cm

5% 10%

Equipment Energy Maintenance

Purchase Cost Cost Cost
Pertimbangkan beaya operasional dari pada hanya
Grafik rata rata
beaya investasi kenaikan
Energi

Anda tidak perlu berhitung

lama lama lagi karena sudah
terbukti!
Friday, December 23, 2022
Step by Step Pemilihan Pompa
Base Frame:
Kaidah instalasi pompa menurut ANSI-HI :
Syarat syarat dan kondisi instalasi Negative suction :
oDiameter pipa naik satu size ukuran pipa komersial dgn
kecepatan air max : 2 m/s
oPosisi pipa Hisap harus miring 6 mm/100 mm
oSuction pipe harus sependek mungkin tetapi tidak kurang
dari 2x Diam Pipa dan harus menggunakan long radius
elbow serta di sisi suction harus free dari gangguan flow.
oPosisi foot valve dengan strainer paling rendah 2 x diam
pipa dan terendam air minimal 4x diam pipa.
Syarat syarat CCONTINUE……..
oHarus ada support untuk pipa dan tidak boleh
menggantung di flange pompa
oMenggunakan ekcentric reducer di sisi suction dan elbow
tidak boleh langsung ke flange pompa.
oKedalaman hisap permukaan air di sesuaikan dengan
perhitungan suction lift agar tidak terjadi kavitasi.
oOperasional duty point pompa di sesuaikan dengan
perhitungan agar tidak terjadi kavitasi atau over capacity.
Syarat syarat dan kondisi instalasi Positive
suction :
oKecepatan air max : 3 m/s
oUkuran pipa naik satu size ukuran pipa komersial.
oPanjang pipa suction berkisar 3x s/d 6x diam Pipa
dan menggunakan long radius elbow.
oPenggunaan isolating valve, flexible connection dan
strainer sangat di anjurkan.
Syarat syarat CONTINUE…….
oHarus ada support untuk pipa dan tidak boleh
menggantung di flange pompa
oMenggunakan ekcentric reducer di sisi suction dengan
posisi bagian miring di atas
oPenggunaan elbow yang tidak boleh langsung ke flange
pompa.
oOperasional duty point pompa di sesuaikan dengan
perhitungan agar tidak terjadi kavitasi atau over capacity.
Instalasi Pompa
PONDASI
Instalasi Pompa
Berbagai jenis Pondasi Pompa

Lantai Pondasi Inersia blok & Inersia blok &

vibration dumper vibration dumper
untuk vertical
in-line pumps
INSTALASI POMPA
Inlet suction condition

Fig A. Fig B.
INSTALASI POMPA
Suction Inlet

Fig A. Fig B.
INSTALASI POMPA
Inlet suction condition

Fig A. Fig B.
INSTALASI POMPA
Bagaimana Cara Menentukan Head Pompa

Formula 1
p 2  p1 V22  V12
H   h2  h1  
g 2 g

Formula 2
Q 4Q
V  
A   D2
Standard end-suction pump – perbedaan
dimensi antara suction dan discharge ports Formula 3
p 2  p1 8  Q2  1 1 
H   h2  h1     4  4 
g g  2  D2 D1 
 INSTALASI POMPA
Bagaimana Cara Menentukan Head Pompa - RUNNING

Standard end-suction pump – perbedaan dimensi

antara suction dan discharge ports
(Example)
Trouble shooting
Masalah yang umum pada pompa
sentrifugal adalah;

 Seal Bocor – Seal rusak

 Flow dan Head tidak sampai ??
 Suara dan Getaran berlebih..
 Alignment or
 Kavitasi or
 Overload-Ampere tinggi
 Pompa tdk running……
Kurva hubungan antara performance pompa dan efisiensi
Diagram yang menunjukan sensitivitas kehandalan pompa dan bagaimana kondisinya
terhadap duty point (BEP – Best Efficiency Point).

Kurva lonceng yang menunjukan

kehandalan pmpa yang diambil dari BEP.

Semakin menjauh dari posisi BEP, akn

menimbulkan masalah di pemeliharaan
seprti yang di tunjukan di kurva pompa.

22
Friday, December 23, 2022 29
Problem Pompa secara umum
Investigasi masalah …...

1. Catatan historical service pompa seperti apa, apakah ada

perubahan? atau lainnya.
2. Investigasi sumber getaran atau kebisingan yang tidak
biasa, dari mana dan bagaimana suaranya ?
3. Lama operasi, kegunaan, dan aplikasi nya apa ?
4. Titik masalah nya dan lokasi dimana?
5. Apakah masalahnya karena masalah instalasi atau pompa
nya sendiri ?
Site Check - Basic

Jika keluhan adalah getaran dan kebisingan,

periksa;

1. Cek alignment pompa dan motor ?

2. Cek frame dan pondasi pompa ?
3. Pipa dan pendukungnya ?
4. Kemungkinan over load/over capacity atau
5. Akibat kavitasi ?
6. Benda lepas apa pun yang terhubung ke pompa
7. Cek viskositas..?
8. Kondisi pompa dan motor ?
Site Check - Basic

Jika maslah nya adalah CAPACITY & HEAD,

Maka check;

Spesifikasi dan perubahan nya jika ada

Apakah pompa sudah sesuai dengan requirement nya?
Priming dan dan membuang angina yang terjebak, di dalam pompa
atau pun di jalur pipa nya
Apakah posisi katup sudah benar?
Kemungkinan kelebihan kapasitas atau kavitasi
Ada yang salah dalam instalasi pompa
Udara masuk di pipa hisap
Kondisi pompa dan motor
Ukur flow dan Pressure ?……
Site Check - Basic

Jika pompa tdk bisa running , check;

1. Sambungan dan suplai listrik
2. Ada sesuatu yang mengganjal pompa sehingga pompa
tidak bisa berputar, cek apakah poros bisa di putar
dengan tangan, lakukan hal yang sama untuk motor
3. Apakah pompa sudah terkopel ke motor?
4. Masalah dengan pompa atau motor
5. Apakah motor starter atau panel control berfungsi?
…..
Common Problems of

Misalignment
1. Getaran dan suara yang tidak perlu
2. Keausan yang tidak perlu pada kopling
3. Komponen pompa rusak sebelum waktu nya
4. Biaya perawatan dan perbaikan yang lebih tinggi
5. Kemungkinan kerusakan pipa, fitting dan aksesori lainnya
6. Kebanyakan kerusakan terjadi pada seal dan bearing.
7. Konsumsi listrik yang lebih tinggi dan suhu bearing yang tinggi.

AND CUSTOMER – COMPLAIN !#@*?&!!

Koreksi Instalasi pompa ?
Pondasi pompa
Koreksi Instalasi pompa ?
Koreksi Instalasi pompa ?
What is The Grundfos Service Objective?

1. It is about reducing
your cost.

2. It is about well
maintained and
efficient pump
systems

3. It is about reliability
and availability
Preliminary Alignment
The preliminary alignment procedure has four steps:
1. Checking coupling clearance
2. Checking soft foot on pump and motor
3. Checking parallel alignment
4. Checking angular alignment
 Types of Alignment

1. Feeler gauge or Steel rule method

(Cheapest, low cost and effective site
practice)

2. Dial Indicator Method (Most common)

3. Laser Method (Most expensive)

Aligment menggunakan Feeler Gauge
Coupling clearance standard
0.08 mm

0.13 mm
Rule of the thumb
 Alignment Tolerance – Pin and Bush Coupling
1 Deg
0.08 mm
Recommended Pump Shaft

RULE of THUMB - Runout /

parallel misalignment shall
not be more than 0.5mm and
0.15mm
angular misalignment of not 0.13 mm
more than 1 Deg.
Motor Shaft
Strongly depends on
coupling manufacturers’
recommendation – Follow it!
BUT MISALIGNMENT CAN HAPPEN DUE TO;
a) Transportation
b) Pipe Stress during installation (Poor pipe to pump alignment)
c) Vibration of other equipments connected to pump
d) Bad foundation – Shoddy workmanship
e) Turbulence or high temperature in the pumping liquid
f) Pump was not pre aligned at site
g) Poor workmanship on pump baseplates and alignments

TYPE OF MISALIGNMENT

a) Parallel – Both axis not at the same level or plane

b) Angular – Both axis are at an angle
c) Lateral (End Float) – Distance between both ends of the axis is incorrect
d) Usually most common misalignment are the combination of the first two. Lateral will
occurs mainly in poorly built baseplate and most coupling can handle it, except in
extreme cases
Most common Types of Misalignment

Angular (Top Picture) and Parallel

(Bottom Picture)
Site Installation
Site Installation
Site Installation
Site Installation

1. Most misunderstanding occurs with negative

suction, suction lift must be considered
when determining the pump head
2. It is dangerous when customer always refer
to the discharge pressure gauge as the
pump head
Site Installation

Good installation comes

with solid and sound pipe
support and equipment
foundation
Installation at the Ground
Installation in High rise Building

We recommend you to install pressure gauges on pump suction and discharge flanges.
The pressure gauge on the suction side must be able to measure vacuum.
OPERATING PUMPS
• Pre-start checks
Pre-start checks has four steps:
1. Bearings
2. Stuffing boxes
3. Pressure gauge
4. Direction of rotation.
5. Coupling, and alignment, grease lubrication on the bearing, shaft should be possible to rotate, motor
driven/engine should be correct direction, electrical panel starter, cable connection etc

• Start up procedure
1. Prime the pump, opening the suction valve, closing the drain, etc, to prepare the pump for operation
2. Start the Motor
3. Open the discharge valve slowly
4. Check for seal leakages, for mech. Seal there should be no leakages
5. For stuffing box sealing, observe the leakages from the stuffing box and adjust the sealing liquid valve proper flow
to ensure the lubrication
6. Check all general mechanical operation of pump and motorThe start-up procedure for HS pumps has four starts
7. Final alignment check.
Operating checks
1. Check pump and piping for leaks.
2. Check and record pressure gauge readings for future reference.
3. Check the differential pressure. If the differential pressure is lower than anticipated,
the motor may be overloaded.
4. Measure motor current consumption and compare the result with the rated current
stated on the motor nameplate. In the event of motor overload, throttle the discharge
isolating/throttle valve until the motor is no longer overloaded.
5. Check bearings for lubrication and temperature. Normal temperature is 70 °C (158 °F).
Maximum temperature depends on the type of lubrication, see the lubricating plate
on the pump.
6. Stop the pump immediately if any defects are noticed.
7. Do not start the pump unless defects have been remedied
MAINTENANCE
• Daily Observation of Pump Operation
1. Daily inspection should be made and any irregularities in the
operation of pumps should be recorded and reported
immediately.
2. This applies particularly to change in sound of running
pump, abrupt change in bearing temperature and seal
chamber leakage.
3. Check of pressure gauges and flow meter, if installed.
4. Check vibration should be made routinely during the day.
5. Check monitoring instrument provided daily, current,
voltage, kW, running hours, vibration level.
Every week
• Visually check for leaks.
• Check for vibrations.
• Hand test bearing housing for any sign of
temperature rise.
• Check correct leaking from stuffing boxes
(approx. 40-60 drops per minute).
MAINTENANCE
• 1/2 annual inspection:
1. For pumps with Stuffing box sealing, the free movement of stuffing box gland should be
checked, gland bolt should be cleaned and lubricated, the packing should be inspected to
determine whether it required replacement.
2. The pumps and driver alignment should be checked and corrected if necessary.
3. Housing for oil lubricated bearings should be drained, flushed and refilled with fresh oil.
4. Grease-lubricated bearing should be checked to see that they contain the correct amount
of grase and that is is still of suitable consistency
5. Check shaft for scores.
6. Check alignment of pump and motor.
7. Check fixing bolts and tighten, if necessary.
8. Check coupling for wear.
MAINTENANCE
• Annual Inspection
1. Vibration trend should be reviewed, if the pump is trending toward unacceptable vibration
level.
1. The bearing should be removed, cleaned and examined for flaws and wear
2. The bearing housing should be carefully cleaned
3. Rolling element bearing should be examined for scratches and wear
4. Immediately after cleaning, rolling element bearing that is consider accepted for re
installed should be coated with grease/oil. If there is any signed of damage the bearing
should be removed and replace.
2. The pumps equipped with shaft packing, the packing should be removed and the shaft sleeve-
or shaft, if no sleeve are used – should be examined for wear.
3. For pumps equipped with mech seal, if the seal were indicating seal of leaking, they should be
removed and returned to the seal manufacture for inspection.
4. Check whether the grease in the pump bearings has hardened.
5. Check rotating assembly for wear.
6. Check wear ring clearances
Lubrication pump bearings
•Recommend relubricating intervals of 2,000 operating hours, depending on duty conditions.

•To refill the bearings with fresh grease, follow this procedure:
•1. Remove the bearing cap.
•2. Add enough grease to fill up 1/3 of the ball bearing.
•3. Note the quantity required.
•4. Replace the bearing cap.

•For every 10,000 operating hours or every two years:

•1. Remove the bearing caps from pump.
•2. Remove old grease.
•3. Thoroughly clean bearing caps.
•4. Refill bearings with fresh grease.
•5. Refill bearing caps completely with fresh grease.
•6. Refit bearing caps in accordance with assembly instructions.
•7. Start the pump briefly several times to distribute the grease in the bearings and to prevent
• overheating of the grease.
References End Presentation