Slide 1:

The honorable Mr Bayu Pratama Purba as my OJT mentor. Good morning everyone.
Im here today to talk to you about my OJT report overhaul propane compressor
024K102. The aim today is to deliver informations and knowledges that I had got in
OJT for 2 months.
Slide 2 :
Hi everyone Im Rayhan. I am from LNG Academy Batch IV in Mechanical & Rotating
concentration. I have done the on job training activity at PT Pertamina (Persero)
Refinery Unit IV Cilacap from 1 July until 31 August 2016. The specific locations are
in workshop and Lube Oil Complex (LOC) II. Initially I was placed in workshop but
because I thought there is no major equipment that brought there so I decided to
follow the Turn Around 2016, especially in LOC II unit 024. Then, I took subject about
Overhaul Propane Compressor 024K102. My mentor from Badak LNG is Mr. Bayu
Pratama Purba who work in Facilities Project Engineering Section. I say thank you to
all parties, so the on job training itself, the report, and also this presentation can be
finished well by me and your help.
Slide 3 :
Before going to my main presentation, let me deliver she-q moment first. Ok Just
look the picture for a while, there are 2 different sides. I analogize the dark room as
bad things and the bright room as good things. I dont compare anything btw. I just
feel grateful, now im in work environment of Badak LNG, always be the first in
safety. In otherwise even the biggest Indonesian oil company, they have commited
to safety but I havent see the implementation. Its good to never show weaknesses
but they must always evaluating. Hopefully our company can keep the good things
and provide benefit to other company as a role model. Cause, Actually your culture
is your brand.
Slide 4 :
Ok, My talk will last about 20 minutes. And I have devided my talk into 6 sections.
First, I will start from the introduction. Then, company profile, next specific
orientation, continue to basic theory, and the main is specific task. Finally, is closed
by conclusion and recommendation. Ok, now lets start with the first point.
Slide 5 :
In the beginning, its always be a good way to start from background, sow, and
objective.
Slide 6 :
First is the reason why I choose Pertamina, because they are the biggest energy
company belong to indonesia, which have many subsidiaries, but I really want the
refinery unit. mainly produce oil and gas that be our commodity nowdays. Besides,
It should be my company next year but I resigned from the program because I hv
joined with LNG Academy at that time, and as cilacap people I never know what is
inside there. So the OJT have already answered my curiousity about that.
Then, it was the right moment we went there, since the turn around 2016 is
scheduled for their routine maintenance and one of them is LOC II the place where I
took the OJT. Actually there is not only overhaul but also inspection for vessel,
cleaning and retubing for HE, but my mentor brought me to 024K102, the propane
compressor. So I followed the overhaul activity from the beginning until finish
 including disassembly, inspection, cleaning, repair, and reassembly to optimize its
work.
Slide 7 :
So, what is covered in this report especially in specific task, there are 3 main
scopes. Activity, Componenet, and measurement.
This report will only cover the procedure of disassembly and reassembly of 024K102
components based on the work that I have seen before. Then, its also important to
know the tools which is used.
Second, There are explanation about the components of propane compressor
024K102 and its replacement but spesificly only in this overhaul Turn Around 2016.
Because it will be different for other compressor condition and engineering
consideration.
last but not least, the measurement only discuss the general information, actually
there is so many list which is done during overhaul this compressor but for now just
some type of measurement only.
Slide 8 :
For the objective from this OJT experience, there are Student are capable to
perform the task that given from industry including to know propane compressor
024K102 specification, overhaul activity, and process that occurs related with this
equipment. Then, we are able to make a good report accordance with the procedure
of scientific writing.
Slide 9 :
Section 2, we will take a look at glance about PT Pertamina (Persero) Refinery Unit
IV Cilacap.
Slide 10 :
PT Pertamina is one of Indonesian state owned enterprises that have been an
experienced player on energy sector in indonesia, even nowdays become known by
the world. Pertamina has some units spread all over Indonesia island, there are
some E&P units, 7 refinery units, 8 marketing units, and other facilities. So, This is
the map of their refinery units
Start from I-VII. The number is the capacity each RU. Im interesting to talk about
RU IV now.And The facts, RU IV capacity is 348 MBSD. It makes them become the
largest capacity and the completest facilities refinery in Indonesia. Another facts,
34% national fuel needs is contributed by RU IV and the percentage in Java Island is
60%. Its awesome, amazing.
Slide 11 :
So, this is PT Pertamina RU-IV Cilacap. It has been established since 1974 and
officially operated on august 24 1976 after authorized by the president of Indonesia
at that time, Mr. Suharto. Its located on Cilacap, central Java. Why? Based on study,
Java is the biggest fuel consumer and it also has ideal natural harbor with deep and
calm sea cause protected by nusakambangan island. Initially, they process crude
oil from middle east but now also from domestic crude oil. The operational area
consist of two main area, this picture is refinery unit and area 70 is near the sea for
crude oil storage.
Slide 12 :
Now, RU IV Cilacap consist of some process units, there are
1. Fuel Oil Complex (FOC), to produce fuel product, oil such as gasoline, naphta,
kerosene, avtur, solar and liquid gas such as LPG and propylene.
2. Aromatic Complex (KPC), to process naphtha from FOC become added value
product such as Paraxylene, benzene, toluene, heavy aromate.
3. Recid Fluid Catalytic Cracking (RFCC), to convert low value product become
high value product in order to increase gasoline, lpg, and propylene production
4. Sulphur Recovery Unit (SRU), to process H2S gas which is produced in unit
that potential to contaminate the environment, by converting become liquid Sulphur
that can be selled as serivatives industrial raw materials.
5. Lube Oil complex (LOC), to produce lube base oil as the main ingredients of
industrial lubricants and its derivatives such as paraffinic oil, minarex, slack wax,
asphalt.
Slide 13 :
In section 3 the specific orientation, I will tell you about Lube Oil Complex II

Slide 14 :
Lube Oil Complex II, usually called by LOC II, was built in 1981-1983. After
debottlenecking in 1998, the mode of lube base oil process is changed from solvex
mode which is physical into hybrid mode which is chemical with adding a new unit,
HTU.
1. Main product are SPO, LMO, and MMO.
2. This is use extraction not distillation process even vacuum condition, because
can cause cracking. propane solvent contact with feed in RDC and produce DAO as
top product and asphalt as bottom product.
3. This also use extraction with furfural solvent, same with before but the top
product is waxy raffinate and bottom product is aromatic, minarex
4. Because in prafin there is component that has high boiling point it can cause
high pour point lube oil, so it removed. It using MEK solvent to separate slack wax
and produce dewaxed oil with some spec.
Slide 15 :
This complex is established to fulfill growth of lube base oil national needs which is
increase rapidly. The feed is ALC long residue from bottom product of CDU, and the
main product of course lube base oil with some spesifications has been explained,
and also there are slack wax for candle,cosmetics,document sealer, minarex for
solvent in print industry to produce better quality, and asphalt for street.
024V112 storage the liquid propane from V113, V114, and condenser. It will be
supplied to V113 if need to separate vapour and liquid form, the liquid will be used
for cooling process in some equipment, in otherwise the gas will be sucked to
compressor. 0.95 kg to first stage and 3.7 to third stage will become 19 kg
discharge pressure. Then, it condense in E129 and the liquid propane store in V112.
Slide 16 :
Section 4, Basic theory will be discuss first before we going to the main section later
Slide 17 :
Compressor is a rotating equipment which has function to moves and increase the
pressure of compressible fluid from one energy level to another by decreasing its
volume.
Slide 18 :
 Compressor is working with giving energy to the air or gas through centrifugal force
which is given by the impeller. The velocity of the gas will be increased, then it is
converted into potential energy as pressure in the diffuser.
Generally, the components of centrifugal compressor is divided into two groups,
rotary component and stationary component. The difference between both of them,
the component will or will not rotate inside the compressor when operating.
Slide 19 :
Definition of Maintenance is an activity which is done to keep performance well,
high realibility, and minimize the damage of the equipment also to keep safety
aspect in working area.
The purposes is To extend lifetime of the equipment.
And here is the classification of maintenance, basicly there are two, planned and
unplanned maintenance. If we havent prepare yet like in emergeny condition, it is
unplanned. But to prevent or minimize the probabilities we do planned
maintenance. PM is based on time, weekly, monthly, or yearly, the activity is
cleaning, inspection and running maintenance. Pdm based on condition same with
CM, there are shutdown is the activity, but the work is overhaul. Major and minor
overhaul depend on the equipment condition.
Slide 20 :
Ok, we enter section 5. this is the specific task about overhaul propane compressor
024K102
Slide 21 :
For this part, I have divided into 7 sections
Slide 22 :
So, this.. The propane compressor looks like. And the specification
The item number is given by the customer, 024 is the unit number, K means
compressor and 102 is equipment number. The size is 2M classified by the
manufacture, DR.
The installed rotor has 7 impeller, but based on the model no. 2M9-7 this
compressor design can be installed until 9 impeller. The serial number given by the
manufacture is 2-7-4797.
This all showed number is design spec from DR, the actual condition the inlet
flow is the hp is the speed is about this with first critical speed 4100 rpm.
The operating temperature is and the first inlet 0.95 kg, the second inlet is 3.7
kg, and disch pressure 19 kg.
Slide 23 :
Now for the sectional view of the compressor, we can see the components from this
direction.
Casing type is horizontally split casing, so they have one pair, this is the
lower hal and the other is upper half.
Based on the construction all the impeller is closed impeller, and based on
the flow the first stage is mixed flow and the rest second until seventh is radial flow
The thrust bearing and journal bearing, both is tilting pad bearing. TB only
one and located in outboard, for JB there are 2 in IB and OB
Next the coupling hub is hydraulic fit coupling which is connected to amriflex
diaphragm coupling but it doesnt show here.
 2 kind of seal are used, contact seal in the rotor IB and OB, and the 14 pairs
laby installed in IGV and diaphragm
For this compressor there are 2 pair inlet wall in first and third stage, 1 pair
discharge wall in last stage, and 6 pairs diaphragm for the rest stage
The rotor assembly is rigid type so the impeller and the shaft is from one
material not using keyed.
Slide 24 :
We have known before that overhaul is one of planned maintenance. So is this, the
work have prepared from long time ago for TA 2016, incluiding shutdown time
consideration, tender, and the important is spare part. The picture show the
moment on TA 2016. This agenda is schedule for 3 area in one times LOC II, III, SRU
for 1 month only, but there is some problem so the progress is late. This agenda
delayed cause some reason, management decision, high customer demand, and
spare part preparation. 024K102 is major equipment because only one unit, and it
based on time, scheduled each 4 years but now almost 6 years. The overhaul is
done by Sulzer who won the tender but DR as manufacture sent representative for
assit. The first target finish on 16 days but late until 20 days because : waiting for
unfinished work, find problem, looking for tools or modified componenet, and
wheather. But finally all equipment can start up well as production spec.
Slide 25 :
There are some recommendation when major disassembly undertake, such as Keep
the compressor and its components are clean, Opening should be covered, ,Extreme
care must be used in handling parts, Be sure that all electric power is off and valve
is closed, Give match marks on mating pieces, Gasket and o-ring must be replaced,
Design clearance refer to manual book, Check all clearance and record for future
reference,
Let me explain the procedure of disassembly
1. First coupling guard and spacer, remove the bolts on it and in flange between
spacer and coupling hub using ring spanner then take it off. After that check the
alignment using laser alignment tools to know initial position before overhaul. Next,
measure DBSE and DBFF using inside micrometer.
2. Remove the four bolts In each pipe flange to compressor using ring spanner
27 mm, then take the pipe off and cover the hole using plaster.
3. Remove 4 proximity probes on each corner and 1 axial probe by rotating its
cover
4. Open all casing bolts, about 35 using hammer wrench 1 inch and copper
hammer to prevent spark. We can use WD-40 for lubricant if hard to open
5. Next is open the end cover by remove 8 bolts and inspection cover 12 bolts
using spanner 1 inch.
6. To open hydraulic fit hub coupling we need enerpac, a hysraulic jack and dial
indicator for checking the movement. Install the pusher ring behind coupling hub as
holder. Assemble high pressure tubing from expander pump to shaft and high
pressure hose from pusher pump to pusher ring. Place the dial indicator on hub.
Purge hydraulic system of all air by open the connector bolts. increase the pusher
pump pressure until ring touching the hub, then increase expander pump pressure
gradually and hold 15-20 minutes to allow for hub expansion. Last release the
pusher pressure by reversing the pump and allow the hub to move out axially.
Slide 26 :
7. Install guide in four corner so the lifting can straight to the up, raise case
upper half approx. 1/8 in by jackscrew located at each corner using ring spanner 1
inch, attach hoisting equipment to eyebolts and adjust it so raised without tilting.
Be sure hoisting eq is adequate for weight. Arrange wooden boards on floor. It must
be raised vertically using crane until well clear of the rotor impeller. Lower case to
floor, resting it on its back then remove the o ring and clean it.
8. Remove lube oil and seal oil pipe using spanner 1 inch. In IB, for lube oil only
one pipe to JB and 2 seal oil pipe. In OB, for lube oil pipe there are 1 to JB, 3 to TB,
and for seal oil 2 pipes.
9. Measure and record the existing data, such as overlap impeller, labyrinth
clearance, JB clearance, TB clearance using some tools. It will be discussed later.
10. Remove capscrew which attach TB cover to bearing housing using allen key
or ratchet wrench 13 mm. Remove the cover. If hard we can hit by the hammer.
Remove gasket between cover and housing. Remove the RTD and hold down bolts
in tilting pad using screwdriver.
11. Same with the hub. But we must remove the nut with spanner and remove
split ring. Measure the dimension and distance using caliper. Install the adapter ring
followed by pusher ring behind thrust disc as holder. Assemble high pressure tubing
from expander pump to shaft and high pressure hose from pusher pump to pusher
ring. Place the dial indicator on TD. Purge hydraulic system of all air by open the
connector bolts. increase the pusher pump pressure until ring touching the TD, then
increase expander pump pressure gradually and hold 15-20 minutes to allow for TD
expansion. Last release the pusher pressure by reversing the pump and allow the
TD to move out axially.
12. Remove the inactive TB, we just pull from the shaft in bearing housing,
detach the RTD and hold down bolt using screwdriver.
Slide 27 :
13. Next journal bearing IB and OB. Remove the dowels and bolts which attach
the bearing caps using ring spanner 1 inch. Lift the bearing caps and top half
bearing housing, handle with care as 2 of 5 babbit come with it. Support the rotor
using hydraulic jack then remove the lower half JB by rotating it around the shaft.
Remove the tilting pad by open the hold down using screwdriver.
14. Remove the seal assembly using ring spanner 1 inch. Remove from cover
seal, outer housing sealm outer seal, inner seal, inner housing seal, laby seal, and
the last shear ring.
15. Wrap webbing sling around rotor and attach to hoisting equipment. Carefully
lift rotor out of case keeping it as level as possible guiding it by hand. After high
enough lift using crane and lower the rotor into cradle and protect seal and bearing
journals from damage and corrosion.
16. For the lower half, just push the guide vane down on one side until the other
side can be pull out from the groove. The inlet guide in the upper half case are
secured by splitline hold down screw. Remove the screw and lift the guide out of the
case.
17. The diaphragm in upper half of compressor case are secured by splitline hold
down screws. Remove screw. Attach hoisting equipment to eyebolt in both side and
use the webbing sling to chain block for lifting. Adjust hoisting equipment and Lift as
level as possible. After removal, dpt the diaphragm nozzle because prone areas.
 Then it will bring for sandblasting to remove dirt or rust using aluminum oxide. It
same for inlet and discharge wall.
18. Open holder bolt using screwdriver, remove the laby by rotating it. If hard we
can use Teflon hammer. Dont forget to give match marks and make it in one place
for checking.
Slide 28 :
There are some recommendation when reassembly undertake, such as
1. Cleaning the internal components and casing.
2. Gasket and o-ring must be in fitst class condition.
3. Inspect all labyrinth and machined surfaces for nicks or burrs.
4. Opening should be covered.
5. Attention to all match marking to ensure correct reassembly.
6. Certain compressor internals are flow-direction sensitive.
The assembly procedure and tools actually almost same, the difference only in the
work order and now its time to put the component back to the intial place exactly
like before overhaul. But, i will just explain the order and something that need
attention.
1. Ok, before install the laby we must check the size and match the order no. first. In
each IGV there are two the small and the big ones. Dont forget to tighten the
stopper so the laby cant go out. Be carefull because laby knife edges are easily
bent.
2. The inlet and discharge walls may be installed by reversing the removal procedure.
For diaphragm, before install to the casing, give the molykote in the groove so it will
be easy for opening in next overhaul. Lower with chain block as level as possible.
Dont forget to install and tighten holding screw in upper half. Back off - turn
after tightening.
3. After fitting new laby, measure impeller cover and spacer diameter and determine
clearance, Lightly file the laby if clearance too small.
4. Next, move the new rotor out from canister using webbing sling and crane then give
anti rust to old rotor and move it into canister.
5. Attch hoisting equipment in rotor lift from cradle and lower until just above the
lower casing then rest using chain blosck
Slide 29 :
6. To install the bearing housing just rotate into the lower casing for lower half, then to
recheck, apply the Prussian blue on shaft where JB pad touch it, rotate the rotor and
if the liquid is loss so its contact well. Next you only to install the upper half.
7. Just reversing the removal procedure from shear ring, laby seal, inner housing seal,
outer and inner seal, outer housing seal finally cover seal
8. The lower half have installed to support the rotor in casing, for the upper half just
put it followed by the bearing cap, tighten the bolts and dowel using ring wrench 1
inch.
9. Clean and put the tilting pad into TB, tighten the hold screw using screwdriver.
Install the RTD cable, install the inactive TB to bearing housing and thrust bushing
to shaft
10.To install the thrust disc its sam the difference, we increase the expander pump
first, than the ppusher pump gradually to push TD using adapter ring until the
proper position reached.
Slide 30 :
11.Install the TP to tB and tighten the bolt using screwdriver, next the RTD Cable,
gasket between bearing civer and housing, Put the active TB and seal ring to
bearing cover. Bring it to bearing housing then tight the bolt using allen key or
wretchet 13 mm
12.Measure and record the new data same when the dissambely process but to ensure
all correct like in manual book
13.Install the lube oil and seal oil pipe using spanner 1 inch.
14.Install the o ring and apply the molykote before put the upper into lower half.
Preapre the guide then lift the upper casing using crane and lower until above the
rotor. Continue with chainblock gradually, and check periodically must level as
possible. When 5 inch, apply copaltite as gasket or sealing compound to minimize
spill possibilities from rough surface.
15.Tighten the bolt casing using hammer wrench and copper hammer. But for now, we
need to know how much the torsion and see the manual book for 2M compressor
with 1 inch bolts, and get 3640 lb/ft. The order also include in manual book like
this. The red circle means there is no bolt in this compressor because this for
general application.
Slide 31 :
16.We must remember expander pump first then pusher pump to push the coupling
hub.
17.Install the end cover and inspection cover back to their initial place
18.Install 4 proximity probe and 1 axial probe than test it in Bently Nevada. Is the
reading is correct or not.
19.Install the rest pipe into the compressor
20.Finally install the spacer and cover by coupling guard. Tighten all the bolts using
spanner.
Slide 32 :
There are 2 measurement during overhaul, existing data and new data. We need
this some tools, With dial indicator we can measure the travel, alignment, or TD
runout. If we want to measure distance, diameter, or thickness we can use caliper
or micrometer, inside outside or for thickness. Feeler gauge and taper gauge has
same function to check clearance, but taper more practice and efficient cause its
design. In otherwise plasti gauge and lead wire, for small clearance. In plastiagauge
we only recheck with the indicator but wire we use caliper to measure the thickness
change.
Silde 33 :
1. DBSE we measure distance between shaft end and DBFF is distance between flange
faces. In order to ensure the coupling will match with this measurement and can
install there
2. To get the rotor optimum, first we adjust the rotor position by overlap impeller data
provided by manufacture, than we only adjust by machining the thrust bushing.
3. Clearance is important in rotating equipment, laby to prevent internal circulation
inside the compressor and leakage,
4. JB clearance using plastigauge put In there install the beraing cap, tighten the bolt,
and find the match thickness in indicator. Compare in spec
5. TB just so so but for axial clearance, using dial indicator in one side than push in
other side. Make zero, than push it will read the total axial.
6. Runout is read by dial indicator, just rotate the rotor to see the toughness or tiltness
of td
7. Shaft diameter is just for make sure the actual rotor same with the spec for this
compressor.
Slide 34 :
Should not be replaced because there is no damage on the component and the
condition is still good enough.
Should be replaced because there is found one or more damage on the component
or to keep the performance
Must be replaced because that components only for disposable or usually called by
consumable parts.
Slide 35 :
1. The overhaul had just already start, everyone can smelled, so we covered all the
compressor with plastic hope the hydrocarbon not going to atmosper its too
dangerous, then looked for the nearest operator and call HSE to gas test again.
2. Because there is no holder for the stopper, only in no 7, so we bring to the shop and
machining to make holder
3. After we looking for 024K102 spare part we still not founf, and on warehouse too, so
we got one its in to the next compressor but the order no is false.
4. We found problem when install the inner part, while support the rotor also install it
by hand
5. Its different between using old rotor and new rotor, we check the dimension of the
first stage of both and in manual book
6. This found last minute after rotor is placed in casing. The design of rotor is slightly
different with previous rotor, so the reading spot is not in position.
7. The bolt is less so we use the old bolt to cover it
Slide 36 :
The last section, conclusion and recommendation. from this activity we can take
some point and give some recommendation
Slide 37 :
PT Pertamina (Persero), An Indonesian state owned enterprises, engaged in oil, gas,
and renewable energy, which have had 7 refinery unit and the largest and
completest is RU IV Cilacap. Not only BBM but also non-BBM product are produced,
one of which in Lube Oil Complex. To keep unit working properly, routine
maintenance excecuted in Turn Around agenda. In TA 2016, 3 unit that have
scheduled are LOC II, LOC III, and SRU. This report spesificly discuss about propane
compressor 024K102 overhaul in LOC II Unit 024 MEK Dewaxing Unit.
1. The classification of propane compressor 024K102 is dynamic compressor, type
centrifugal, multistage, and horizontally split casing. The function is to compress
and increase the propane pressure from 0.95 to 19 kg
2. Overhaul in TA 2016 is planned maintenance which is done based on operation time
(time based), the purpose is to check, repair and/or change all compressor
component completely
3. The procedure of aseembly and disassembly in TA 2016 have followed SOP in
manual book from manufacture and the work order arranged by planner
4. There are 3 option of component replacement, should not, should, or must be
replaced. And the good news there are no red notes for next overhaul activity for
this compressor
5. Overall for the result is good, because after overhaul and starup have done, this
compressor work normally as its function and propane pressure needs has been
reached.
Slide 38 :
And here are the recommendation, Since overhaul agenda is scheduled for long
time before the preparation should be well if there is no obstacle, this work can be
finished as first target, 20 days become 16 days. So to make it smooth, spare part
material should be given more attention. By doing earlier and tighter screening of
material. Because if there are mistaken, the material can be returned back to
vendor and replace for the new ones. In the end, material are fully prepared and
stored well in warehouse before overhaul time. The other, related to Pertamina
commitment about safety like my SHE-Q moment in the beginning, generally all
refinery area and Especially When overhaul take place in shop and area, all person
must use standard ppe, from worker mechanic, inspector, operator until us who not
related with the task. Because comfort not always safety, but safety always can
minimize the risk that can come anytime.
Slide 39 :
Okay thats my presentation, is there any question?
Slide 40 :
I think thats all from me. Im sorry for all my mistakes and weekneses. Thank you
for your attention.