1.

0 INTRODUCTION 5

1.1 Purpose of Report 5

1.2 Equipment Details 7

1.3 Abbreviation 8

2.0 PROBLEM STATEMENT 9

2.1 Erosion-corrosion 9

2.2 Two Body Abrasive Wear 9

2.3 Three Body Abrasive Wear 10

2.4 Particle Impingement 10

2.5 Pumps in Abrasive Service 10

3.0 IMPROVEMENT PROPOSAL 12

3.1 Impeller Improvement 12

3.2 Improvement of Pump Components 28

3.3 Improvement of Centre Sleeve and Centre Bushing 37

3.4 Improvement of Throat Bushing 40

3.5 Improvement of Stage Piece and Stage Sleeve 43

3.6 Improvement of Shaft 46

3.7 Pump Casing 47

3.8 Erosion Analysis of Sumandak COTP P-1320 A 54

4.0 REENGINEERED AND REJUVENATE SOW 61

5.0 CONCLUSION 63

6.0 APPENDICES 64

7.0 REFERENCES 67
FIGURES
Figure 2.1: Pump in Abrasive Service 10
Figure 3.1:: Tripeller 13
Figure 3.2: Front Shroud with Slots to be Inserted with Vanes 15
Figure 3.3: Vanes Protrusion Design 15
Figure 3.4: TIG Welding Jig for Tripeller 16
Figure 3.5: Tripeller Joint Area for Welding 16
Figure 3.6: Example Severe damaged area (P-1320 A) 18
Figure 3.7: Example Severe damaged at Back Shroud (P-1320 A) 19
Figure 3.8: Example of Stellite 6 Cladding on Impeller 19
Figure 3.9: Safety Factor of Weldment at the front Shroud 21
Figure 3.10: Location of simulated area for flow analysis in estimating pump performance curve
based on P-1320 A 22
Figure 3.11: Pump performance curve for multistage pump (Total of 4 stages) 23
Figure 3.12: Wear Ring Location in Sumandak Pump P-1320 A 36
Figure 3.13: Design of Center Bushing with Center Sleeve 38
Figure 3.14: Damage area at Throat Bushing at Pump P-1320 A 40
Figure 3.15: Coating Area of the Internal Volute 47
Figure 3.16: Balance pipeline at the bottom casing for P-1320 A 48
Figure 3.17: Certain painted area on pipeline is scrapped and cleaned for NDT 49
Figure 3.18: Crackspotted on the straight line of the pipe. 50
Figure 3.19: 3D Model of Proposed Pipeline 51
Figure 3.20: List of items in the proposed design 52
Figure 3.21: Section view of the proposed pipeline 52
Figure 3.22: Location of simulated area for erosion analysis 54
Figure 3.23: An example of abrasive attack on both wear ring impeller eye wear ring case eye 54
Figure 3.24: Velocity distribution near WRIE and WRCE area 55
Table 1 1: Overview of Proposed Improvement & Rectification on Pump Parts 6
Table 1 2: P-1320 B COTP Technical Data 7
Table 2 1: Explanation on Figure 2.1 11
Table 3 1: Stellite 6 Chemical Composition 17
Table 3 2: Stellite 6 Chemical Composition 18
Table 3 3: Simulation results of head increase at various flow rate for each stage 22
Table 3 4: Simulation Data 23
Table 3 5: Velocity profile and vector on stage 4 impeller and volute 24
Table 3 6: Fluid Flow at impeller trailing edge of stage 4 25
Table 3 7: Pressure distribution on impeller blade and volute 26
Table 3 8: Material Properties Comparison between A276 SS & Super Duplex (UNS S32760) 29
Table 3 9: : Comparison between Original Design and Proposal Design 30
Table 3 10: Stellite 1 Chemical Composition 32
Table 3 11: Stellite 1 Physical Properties 32
Table 3 12: Material Properties Comparison A747 Grade CB7CU-1 &Duplex Alloy (UNS S32205) 32
Table 3 13: Comparison between Original Design and Proposal Design 33
Table 3 14: Explanation on Figure 23 35
Table 3 15: Comparison between Current Design and Proposal Design 39
Table 3 16: Material properties comparison between A743 CA15 and Duplex Alloy (UNS S32205) 39
Table 3 17: Comparison between Original design and Proposal Design 41
Table 3 18: Material Comparison A747 Grade CB7CU-1 & Duplex Alloy (UNS S32205)) 43
Table 3 19: Material Comparison A276 SS 410 HT429 & Duplex Alloy (UNS S32205) 43
Table 3 20: Comparison between Current Design and Proposal Design 44
Table 3 21: Material Properties Comparism between AISI 410 and UNS S32760 46
Table 3 22: Material Properties for Belzona 1341 (Supermetalglide) 47
Table 3 23: NDT on the balance pipeline 50
Table 3 24: List of material of current and proposed pipeline 53
Table 3 25: Comparison between Current Design and Proposal Design for WR Impeller Eye 56
Table 3 26: Comparison between Current Design and Proposal Design for WR Case Eye 58
Table 4 1: General R&R Scope of Work 61