PT.

TORISHIMA GUNA ENGINEERING

FINAL REPORT

CUSTOMER : CHEVRON GEOTHERMAL SALAK.LTD

TYPE : 5 TUT 16 C 3

MANUFACTURER : PEERLESS PUMP

REF No. : SO 4313 0049 / SR No. 1250788 01 09043 000

REPORT No. : SRV - TGE - 13 039

 This report is exclusive property of
PT TORISHIMA GUNA ENGINEERING (the company)
and shall not duplicated, used, transferred or disclosed to other except
as authorized by contract and the written conset with the company
FINAL REPORT
his report is exclusive property of
IMA GUNA ENGINEERING (the company)
ated, used, transferred or disclosed to other except
contract and the written conset with the company
PT. TORISHIMA GUNA ENGINEERING

FINAL
INSPECTION
REPORT

APPROVAL BY CHECKED BY INSPECTED BY

 QA Manager Prima Reza F Sofyan hadi
March 13th, 2014 March 13th, 2014 March 13th, 2014
 FINAL
NSPECTION
REPORT

INSPECTED BY
 Sofyan hadi
March 13th, 2014
PT. TORISHIMA GUNA ENGINEERING

TABLE OF CONTENT

Overhaul Service Peerless PUMP ( 5 TUT 16 C3 - 1 STAGE ) Pump Unit S0 4313 0049

at PT Torishima Guna Engineering

Pump Overhaul Service Flow Process :
1 Incoming
Visual inspection for Pump condition After unloading from truck, Pump type and general Pump
condition on
May 21st, 2013(Pic : PPC, Workshop, QC)

2 Dismantling
Dismantling as follow Casing Upper Lower, Left & Rigth Hand Impeller, Rotor Assy, Pump Shaft, Bolt

Casing Pump removing the pump bolt casing And after dismantling perform mechanical cleaning.
(Pic : PPC, Workshop,
QC)

3 Invertigation of Pump ( PIC. QC, Engineering )

- Visual inspection method was done for investigation of the pump.
Outside and Inside Micrometer, Vernier Caliver, Deph Gauge, Dial gage, Faro Arm, Dept gauge
-
were used to
measure all pumps part.
- Perform reverse Engineering based on measurement inspection result of parts condition
- Make a list of all investigasion pump parts based on measurement inspection result of parts pump.
- Drawing of the parts for fabrication and recommended condition of parts

4 Replacement Parts And Caoting

Based on the overall results of the pump insvestigation decided to do a replacement of pump parts,
as follows:
A. Parts Replacement :
Right Hand Casing Ring Interstage Bushing
Left Hand Casing Ring Key Impeller
Shaft Sleeve DE & NDE Key Coupling
Interstage Sleeve Key Interstage
Interstage Sleeve A Pump Shaft
B. Parts Recondition Casing :
Lower Casing
Upper Casing
Recodition with Rebuild Inner casing Lower & Upper Casing with devcon and Caoting with belzona
1321 and belzona 1111. Total thickness of the coating : 402 - 588 micron ( see page : 73 )

5 Balancing
Performed balancing rotor set using balancing machine (Schenck) with the following result ; 0.18 Which
is lower then the dynamic of balance reference grade 2.5
(Pic : Workshop, QC)
TABLE OF CONTENT

p parts based on measurement inspection result of parts pump.

ng Lower & Upper Casing with devcon and Caoting with belzona

alancing machine (Schenck) with the following result ; 0.18 Which

PT. TORISHIMA GUNA ENGINEERING

TABLE OF CONTENT

6 NDT - PENETRANT
NDT penetrant inspection performed on the impeller, left and Right hand casing ring, shaft sleeve DE and NDE,
interstage sleeve, interstage bushing, Pump Shaft with the following, result ; No crack or no indication crack
and No indication linier.
NDT inspection of the pump casing is not done because there is no implementation of heating or welding process
on theupper and lower casing.
7 Assembling
Before assy all pump parts, visual and dimensional inspection were done to make sure whole parts condition
already
inspected. Result : OK
The pump assembling process, obtained :
Total Gap Value : 8.6 mm
End Play Value : 15 mm
Thickness Gasket Casin : 0.5 mm

8 Water Pressure Test / Hydrostatic

Perform inspection for leaks of the pump casing :
Water pressure test : 140 Psi ( 10 Bar )
Tested with : Water
Holding time : 30 Minutes
Result : No leakage

9 Painting
The pump unit was painted Rose White

10 Final Inspection
After assembling, visual inspection for the overall condition of the pump was done, the result; OK
Result of measurement inspection for rotor setting, Total gap 8.6 mm and endplay 15 mm
Water pressure test for pump with pressure 140 Psi, 10 Kg/cm, result : No leakage
NDT penetrant inspection performed on the impeller, left and Right hand casing ring, shaft sleeve DE and ND
interstage sleeve, interstage bushing, Pump Shaft with the following, result ; No crack or no indication crack
and No. indication linier.
TABLE OF CONTENT

n the impeller, left and Right hand casing ring, shaft sleeve DE and NDE,
Pump Shaft with the following, result ; No crack or no indication crack

not done because there is no implementation of heating or welding process

dimensional inspection were done to make sure whole parts condition

med on the impeller, left and Right hand casing ring, shaft sleeve DE and NDE,
ing, Pump Shaft with the following, result ; No crack or no indication crack
PT. TORISHIMA GUNA ENGINEERING

TABLE OF CONTENT

NO DESCRIPTION

Dimension And Data Inspection Record

1 Received Dimensional Inspection Report Right Hand Casing Ring
2 Received Dimensional Inspection Report Left Hand Casing Ring
3 Received Dimensional Inspection Report Shaft Sleeve DE & NDE `
4 Received Dimensional Inspection Report Interstage Sleeve
5 Received Dimensional Inspection Report Interstage Sleeve A
6 Received Dimensional Inspection Report Interstage Bushing
7 Received Dimensional Inspection Report Key Impeller
8 Received Dimensional Inspection Report Key Coupling
9 Received Dimensional Inspection Report Key Interstage
10 Received Dimensional Inspection Report Casing Lower
11 Received Dimensional Inspection Report Casing Upper
12 Received Dimensional Inspection Report Left Hand Impeller
13 Received Dimensional Inspection Report Right Hand Impeller
14 Received Dimensional Inspection Report Pump Shaft
15 Final Dimensional Inspection Report Shaft Collar
16 Final Dimensional Inspection Report Water Deflector DE and NDE
17 Final Dimensional Inspection Report Bearing Hosuing DE
18 Final Dimensional Inspection Report Bearing Housing NDE
19 Final Dimensional Inspection Report Bearing Cover DE and NDE
20 Final Dimensional Inspection Report Lantern Ring DE and NDE
21 Final Dimensional Inspection Report Packing Gland De and NDE
22 Final Dimensional Inspection Report Right Hand Casing Ring
23 Final Dimensional Inspection Report Left Hand Casing Ring
24 Final Dimensional Inspection Report Shaft Sleeve DE & NDE
25 Final Dimensional Inspection Report Interstage Sleeve
26 Final Dimensional Inspection Report Interstage Sleeve A
27 Final Dimensional Inspection Report Interstage Bushing
28 Final Dimensional Inspection Report Key Impeller
29 Final Dimensional Inspection Report Key Coupling
30 Final Dimensional Inspection Report Key Interstage
31 Final Run Out Inspection Report Pump Shaft
32 Final Run Out Inspection Report Rotor Assy
33 Final Dimensional Inspection Report Casing Lower
TABLE OF CONTENT
PT. TORISHIMA GUNA ENGINEERING

TABLE OF CONTENT

NO DESCRIPTION

Final Dimensional Inspection Report Casing Upper 35

Final Run Out Inspection Report Left Hand Impeller 36
Final Run Out Inspection Report Right Hand Impeller 37
Final Balancing Inspection Report Static Balancing Left Hand Impeller 38
Final Balancing Inspection Report Static Balancing Right Hand Impeller 39
Final Balancing Inspection Report Dynamic Balancing Rotor Set 41
Final Residual Unbalance Check Six Point Residual unbalance 42
Final Clearance Inspection Report Pump 45
Photograph Inspection Record
1 Received Photograph Record Incoming Pump
2 Received Photograph Record Dismatle Casing Upper Lower
3 Received Photograph Record Dismantle Rotor Set and Parts Pump
4 Received Photograph Record New Spare Parts Of Pump (Fabricate )
5 Final Photograph Record NDT Fabricate Parts using Liquid Penetrant
6 Received Photograph Record Inspection Facing Foot and Casing Flatness
7 Received Photograph Record Recondition Casing Upper Lower
8 Final Photograph Record Inspection Casing Flatness
9 Final Photograph Record Static Balancing Right Hand Impeller
10 Final Photograph Record Dynamic Balancing Rotor Assy
11 Final Photograph Record Inspection Casing After Remachining
12 Final Photograph Record Coating Casing Upper Lower
13 Final Photograph Record Inspection Clearance with Plastic Gauge
14 Final Photograph Record Assembling Rotor Set
15 Final Photograph Record Assembling Rotor Assy on Casing Lower
16 Final Photograph Record Assembling Upper Casing on Lower Casing
17 Final Photograph Record Install Gland Packing on packing sleeve
18 Final Photograph Record Install Dowel Pin and Nut
19 Final Photograph Record Install Casing Jact bolts
20 Final Photograph Record Install Venting Tube
21 Final Photograph Record Pump Water Pressure Test
22 Final Photograph Record Painting Pump
TABLE OF CONTENT

35
36
37
38
39
41
42
45
PT. TORISHIMA GUNA ENGINEERING

TABLE OF CONTENT

NO DESCRIPTION

ENCLOSER
1. Time Schedule Overhaul of Peerless pump
2. Inspection And Test Plan ( ITP ) Overhaul of Peerless pump
3. Hardness Test Report
4. Parts Investigation Report For Overhaul Pump
5. NDT With Penetrant Inpection
6. Materials Certificate of parts fabricated
7. Certificate calibration of Pressure gauge
8. Certificate of Warranty
TABLE OF CONTENT
PT. TORISHIMA GUNA ENGINEERING

DIMENSION
&
DATA
INSPECTION REPORT

RECEIVED
FI 7.5-04/03-01
Rev.1
Edisi A
MENSION
&
DATA
CTION REPORT

ECEIVED
PT. TORISHIMA GUNA ENGINEERING

DIMENSIONAL INSPECTION REPORT

CUSTOMER : CHEVRON GEOTHERMAL SALAK, LTD MFG : PEERLES PUMP COMPANY

SERVICE : OVERHAUL OF PUMP PUMP TYPE : 5 TUT 16C3
PART NAME : RIGHT HAND CASING RING MATERIAL : AISI 410
REF. NO. : SO 4313 0049 / RS. 1250788 01 09043 000 PART NO. : 7

X AS RECEIVED AS FINAL OEM FABRICATION RECONDITION

0

270 90

180

Unit : Milimeter
Note :

Recommendation :

FI 5.7.1 - 09
Rev.1
JUDGEMENT APPROVED BY CHECKED BY INSPECTED BY
AS RECEIVED Name : Hambali Name : Sofyan hadi Name : Anto K
Date : Date : Date :

NG Sign : Sign : Sign :

Page :

FI 5.7.1 - 09
Rev.1
ONAL INSPECTION REPORT

PEERLES PUMP COMPANY

5 TUT 16C3
AISI 410
7

RECONDITION

Milimeter

FI 5.7.1 - 09
Rev.1
 INSPECTED BY
Anto K

FI 5.7.1 - 09
Rev.1
PT. TORISHIMA GUNA ENGINEERING

DIMENSIONAL INSPECTION REPORT

CUSTOMER : CHEVRON GEOTHERMAL SALAK, LTD MFG : PEERLES PUMP COMPANY

SERVICE : OVERHAUL OF PUMP PUMP TYPE : 5 TUT 16C3
PART NAME : RIGHT HAND CASING RING MATERIAL : AISI 410
REF. NO. : SO 4313 0049 / RS. 1250788 01 09043 000 PART NO. : 7

X AS RECEIVED AS FINAL

TEST DATA EVALUATION OF DATA

1. Specific Unbalance ( e )
Residual Unbalace Correction Plane

UI 1057.050
UI = 1057.05 g.mm 1360.00 degree eI = = = 0.00220 mm
(m/2) . 1000 480.5 x 1000

U II = #REF! g.mm 102 degree

U II 1360.000
e II = = = 0.00283 mm
(m/2) . 1000 480.5 x 1000

Rotor Weight m = 961 kg 2. Balance Quality ( G )

Max. Service Speed n = 1475 Rpm eI.n 0.00220 x 1475

G = =
9.55 9.55
= 0.34 mm/s

I II
3. Judgement
Balance Radius 145 250 mm
Criteria
Residual Unbalance Weight 7.29 5.44 gr = G 6.3 or less

Origin Unbalance Weight 7.29 5.44 gr Result = 0.34

Unit : Milimeter
Note :

Recommendation :

FI 5.7.1 - 09
Rev.1
JUDGEMENT APPROVED BY CHECKED BY INSPECTED BY
AS RECEIVED Name : Hambali Name : Sofyan hadi Name : Anto K
Date : Date : Date :

NG Sign : Sign : Sign :

Page :

FI 5.7.1 - 09
Rev.1
ONAL INSPECTION REPORT

PEERLES PUMP COMPANY

5 TUT 16C3
AISI 410
7

mm

mm

Milimeter

FI 5.7.1 - 09
Rev.1
 INSPECTED BY
Anto K

FI 5.7.1 - 09
Rev.1
PT. TORISHIMA GUNA ENGINEERING

DIMENSION
&
DATA
INSPECTION REPORT

FINAL
MENSION
&
DATA
CTION REPORT

FINAL
PT. TORISHIMA GUNA ENGINEERING

RUN OUT INSPECTION REPORT

CUSTOMER : CHEVRON GEOTHERMAL SALAK, LTD MFG : PEERLES PUMP COMPANY

SERVICE : OVERHAUL OF PUMP PUMP TYPE : 5 TUT 16C3
PART NAME : PUMP SHAFT MATERIAL : AISI 410
REF. NO. : SO 4313 0049 / RS. 1250788 01 09043 000 PART NO. : 6

AS RECEIVED X AS FINAL OEM X FABRICATION RECONDITION

270 90

180

A B C D E F G H

POSITION A B C D E F G H
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
90 0.000 0.000 0.000 0.000 0.000 0.000 - 0.010 0.000
180 0.000 0.000 - 0.010 - 0.010 - 0.010 - 0.010 0.000 0.000
270 0.000 0.000 - 0.015 - 0.010 - 0.010 - 0.015 - 0.010 0.000

Unit : Milimeter
Note :
Measurement : Dial Indicator 0 - 10 mm Accuracy 0.01 mm
Acceptance Run Out Standard 0.03 mm

FI 5.7.1 - 03
Rev.1
JUDGEMENT APPROVED BY CHECKED BY INSPECTED BY
AS FINAL Name : Hambali Name : Sofyan hadi Name : Anto K
Date : November 11th, 2013Date : November 11th, 2013Date : November 11th, 2013

OK Sign : Sign : Sign :

Page :

FI 5.7.1 - 03
Rev.1
OUT INSPECTION REPORT

PEERLES PUMP COMPANY

5 TUT 16C3
AISI 410
6

RECONDITION

D E F G H

Milimeter

FI 5.7.1 - 03
Rev.1
 INSPECTED BY
Anto K
November 11th, 2013

32

FI 5.7.1 - 03
Rev.1
PT. TORISHIMA GUNA ENGINEERING

RUN OUT INSPECTION REPORT

CUSTOMER : CHEVRON GEOTHERMAL SALAK, LTD MFG : PEERLES PUMP COMPANY

SERVICE : OVERHAUL OF PUMP PUMP TYPE : 5 TUT 16C3
PART NAME : ROTOR ASSY MATERIAL : -
REF. NO. : SO 4313 0049 / RS. 1250788 01 09043 000 PART NO. : -

AS RECEIVED X AS FINAL OEM FABRICATION RECONDITION

0

270 90

180

POSITION A B C D E F G H I
0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
90 0.000 0.000 0.000 - 0.010 - 0.010 - 0.020 + 0.020 - 0.010 0.000
180 - 0.010 0.000 + 0.025 + 0.020 - 0.030 + 0.010 + 0.015 0.000 0.000
270 - 0.010 0.000 + 0.005 + 0.010 - 0.020 + 0.015 + 0.020 0.000 0.000

Unit : Milimeter
Note :
Measurement : Dial Indicator 0 - 10 mm Accuracy 0.01 mm
Acceptance Run Out Standard 0.03 mm

FI 5.7.1 - 03
Rev.1
JUDGEMENT APPROVED BY CHECKED BY INSPECTED BY
AS FINAL Name : Hambali Name : Sofyan hadi Name : Anto K
Date : November 11th, 2013Date : November 11th, 2013Date : November 11th, 2013

OK Sign : Sign : Sign :

Page :

FI 5.7.1 - 03
Rev.1
OUT INSPECTION REPORT

PEERLES PUMP COMPANY

5 TUT 16C3
-
-

RECONDITION

Milimeter

FI 5.7.1 - 03
Rev.1
 INSPECTED BY
Anto K
November 11th, 2013

33

FI 5.7.1 - 03
Rev.1
PT. TORISHIMA GUNA ENGINEERING

PHOTOGRAPH
RECORD
OTOGRAPH
RECORD
PT. TORISHIMA GUNA ENGINEERING

PHOTO RECORD

CUSTOMER : CHEVRON GEOTHERMAL SALAK, LTD MFG : PEERLES PUMP COMPANY

SERVICE : OVERHAUL OF PUMP PUMP TYPE : 5 TUT 16C3
PART NAME : RIGHT HAND CASING RING MATERIAL : AISI 410
REF. NO. : SO 4313 0049 / RS. 1250788 01 09043 000 PART NO. : 7

X AS RECEIVED AS FINAL OEM FABRICATION RECONDITION

0

270 90

180

Unit : Milimeter
Note :

Recommendation :
 JUDGEMENT APPROVED BY CHECKED BY INSPECTED BY
AS RECEIVED Name : Hambali Name : Sofyan hadi Name : Anto K
Date : Date : Date :

NG Sign : Sign : Sign :

FI 7.5-04/03-01
Rev.1
Page :
Edisi A
PHOTO RECORD

PEERLES PUMP COMPANY

5 TUT 16C3
AISI 410
7

RECONDITION

Milimeter
INSPECTED BY
Anto K

1
PT. TORISHIMA GUNA ENGINEERING

PHOTO RECORD

CUSTOMER : CHEVRON GEOTHERMAL SALAK, LTD MFG : PEERLES PUMP COMPANY

SERVICE : OVERHAUL OF PUMP PUMP TYPE : 5 TUT 16C3
PART NAME : RIGHT HAND CASING RING MATERIAL : AISI 410
REF. NO. : SO 4313 0049 / RS. 1250788 01 09043 000 PART NO. : 7

X AS RECEIVED AS FINAL OEM FABRICATION RECONDITION

0

270 90

180

Unit : Milimeter
Note :

Recommendation :
 JUDGEMENT APPROVED BY CHECKED BY INSPECTED BY
AS RECEIVED Name : Hambali Name : Sofyan hadi Name : Anto K
Date : Date : Date :

NG Sign : Sign : Sign :

FI 7.5-04/03-01
Rev.1
Page :
Edisi A
PHOTO RECORD

PEERLES PUMP COMPANY

5 TUT 16C3
AISI 410
7

RECONDITION

Milimeter
INSPECTED BY
Anto K

1
PT. TORISHIMA GUNA ENGINEERING

ENCLOSER
FI 7.5-04/03-01
Rev.1
Edisi A
NCLOSER