indahkiat

pulp and paper products

Making Joint Valve 3” on the Outlet & Inlet Line Pipe

Centrifugal Pump at OPU #2
for Prevent Cavitation

Engineering & Maintenance - Mechanical Utility BROKE

No Reg: 2023/8368/JDI/21785 COST

2023 2nd Half Intra Mill JDI Competition OEE

May, 21th 2024 CCI

By : Jaka Pamungkas (1111036) EBITDA

 One Page Summary
Just Do It
Competition Period Intra Mill 2024
Project timeline Making Joint Valve 3” on the Outlet & Inlet Line Pipe
Start Date 01-Oct-23 Centrifugal Pump at OPU #2 for Prevent Capitation Improvement Area OPU #2
End Date 30-Nov-23

Project Leader Jaka Pamungkas NIK 01111036 Division Engineering Section MTC Utility
Collaborate Team 1. Billy Ahmad 2. Angga 3. Nova

BEFORE AFTER
Description Description

Before JDI pump OPU#2 Capitation because Affter JDI pump OPU#2 good condition and ready
level river water low supply raw water to process FWT.

Quantitative
1. Reduce cost spare part Impeller Pump
1 Unit Impeller IDR 60.000.000
2. Reduce loss energy pump OPU#2
Loading pump (Capitation Condition) , I =200 A
(P) = √3 x V x I x Cosϸ
= ( √3 x 380 x 200 x 0.05) x 1 Hour
= 111,9 kwh
BENEFIT
Qualitative
3. Reduce Cost Loss Pump OPU#2 Q = Reduce Customer Complain
Cost Per kwh = IDR 1.114,74 C = Reduce Cost IDR 119.874.915
D = Continue Supply Raw Water to Process at FWT
= 111,9 kwh x 16 jam x IDR 1.114,74 S = Improve A void Work Accident
= IDR 1.995.831 /day M = Skill Employee
= IDR 59.874.915 /Month

Analysis Problem :
Machine design
The impact dry season on centrifugal
pump can cause capitation
Background
Impeller Centrifugal Pump Root Cause :
Impact low level river can
1 cause capitation
Cracked impeller pump
2

Thermodynamics To Process FWT 3 Raw water supply to the

process is disrupted
Low Efficiency pump & High
Temperature

Materials science
Cracked impeller pump.

LEVEL
6
Fluid mechanics 5
Capitation centrifugal pump. Centrifugal Pump - D 4
OPU #2 3
2
1
 Implementation
Lay Out Process Centrifugal Pump - OPU #1 & OPU#2

OPU #2

OPU #1

Lagoon #2
 Implementation
Material Process modification Check & Monitoring
Before Action

To Process FWT

Before Action : Prepare Tool & - Prepare parts - After adding the pump,
- The pump experiences Material : - Fabrikasi it did not experience
capitation - Valve 3” - Welding capitation
- Vibrasi - Pipe 3” - No vibration occurs
- can't suck it - Elbow 3” - The process of supplying
- Flange 3” water to the FWT LEVEL
becomes smooth
6
5
Centrifugal Pump - D
4
OPU #2
3
2
1
 Benefit & User Satisfaction

QUALITY Reduce cost spare part Impeller Pump

Reduce Customer Complain
1 Unit Impeller = IDR 60.000.000
= USD 3.817,04

COST Reduce loss energy pump OPU#2

Reduce Reduce Cost IDR 119.874.915
Loading pump (Capitation Condition) , I =200 A
(P) = √3 x V x I x Cosϸ
DELIVERY Continue Supply Raw Water to = ( √3 x 380 x 200 x 0.85) x 1 Hour
= 111,9 kwh
Process at FWT
Reduce Cost Loss Pump OPU#2
SAFETY Cost Per kwh = IDR 1.114,74
Avoid Work Accident
= 111,9 kwh x 16 jam x IDR 1.114,74
= IDR 1.995.831 /day
MORAL = IDR 59.874.915 /Month
Improve Skill Employee = USD 3.809,08

Total Benefit
USD 7.626,12
THANK YOU