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SLIDE 1

Ladies and gentlemen, good morning everyone. I am very happy today to have the
opportunity to be present before all of you gentlemen.
In the next twenty minutes, I will explain to you all about the my final presentation entitled
"Installation and Commissioning of the New Centrifugal Air Compressor Centac C700"

SLIDE 2

My name is Muhammad Rizky, I'm 23 years old from Lhokseumawe, Aceh. Alumni of
Mechanical Engineering Polytechnic state of lhokseumawe. I was mentored by Mr. Fajar
Suryonugroho and assisted by Mr. Mukhidin, Mr. Rony and also Mr. Erwin Sirait. I gained a
lot of experience from the following great people during the GT period at PT Toba Pulp
Lestari.

SLIDE 3

PT Toba pulp Lestari is one of the leading pulp producers in Indonesia, whose mission is to
be one of the largest, best-managed and sustainable resource-based groups, creating value
for the community, country, climate, customers and company of course. The vision of PT
Toba Pulp Lestari is to Improving lives by developing resources sustainably.

So that the work I do provides maximum benefits for the company where I work, namely PT
Toba Pulp Lestari, I must implement a work culture in accordance with the core values of
the company, namely: Complementary Team, Ownership, People, Integrity, Costumer and
Continuous Improvement.
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SLIDE 4

There are four outlines that I will discuss in the final of my presentation today, namely:
Compressor Installation, Compressor Commissioning, Performance Monitoring and
Preventive Maintenance and I also discussed a summary of my second and third
presentations during the GT period, including my daily activities.

SLIDE 5

Compressor is a mechanical device used to provide energy to the air, so that air can flow
from one place to another continuously. For example, to move air from point A to point C,
we use a compressor that is at point B, then the pressure P3 must be less than P2 so that air
can flow to its destination, point C.

On this occasion I focus on the Centrifugal Compressor, namely: a compressor with the
working principle of converting the air velocity energy generated by the impeller action
which rotates from the mechanical energy of the driving unit to potential energy in the
diffuser. (When the impeller rotates and the outside air is inhaled, the temperature will rise,
the pressure increases and the volume of the air decreases.

SLIDE 6

The incoming air is inhaled by the compressor impeller will experience an increase in
temperature, then the exit air must be cooled using a cooler and then also separated the
water content in the air using moisture separators. And the product air output is as we
expected.
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Here are the main components for the centac C700 compressor:

a. Rotor assembly
Each rotor assembly consist of an efficient and high quality stainless steel impeller
and a removal thrust collar mounted on a helical geared pinion shaft. the impeller is
secured to the shaft by a taper attachment and the thrust collar is secured to the
shaft with a polygon attachment. all rotating parts are dynamically balanced as a
complete assembly
b. Bearing
Thrust loads are absorbed at each pinion by a hydrodynamic thrust bearing. the
thrust bearing are designed to maximize load carrying capacities and to minimize
power loss
The journal bearing are babbitt lined, fixed tilted pad design for maximum stability
and load capacity with minimum power loss
bullgear bearings for centac compressor models incorporate a hydrodinamic design.
c. Seal
a single cartridge seal is mounted in the plain bearing housing behind each impeller.
each cartridge consists of three, one piece, fully floating non-contact carbon rings.
one ring is used as an air seal and the remaining two as oil seal. buffer air supplies air
to the oil seal assuring that lube oil is not drawn past the seals, thus ensuring oil free
air.
d. Intercooler
The centac cartridge cooler is internal to the compressor casing. the coolers are
dunot type, with the water over the tubes. the tubes are internally finned. air passes
through the tubes while the water makes a number of counter passes to the air flow.
this arrangment results in highly efficient heat transfer or exchanger.
The internal fin design, along with the straight through tube design, produces the
best heat transfer and lowest pressure drop.
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Cooler design features :

SLIDE 7

There are two types of compressors used in PT Toba Pulp Lestari, namely Centrifugal in the
Oxygen Plant and Energy area, for Reciprocating types also in the oxygen plant area.

SLIDE 8

Here are the design specifications of the Centac C700 Air Compressor, with a capacity of
5,886 Nm3/H and a pressure of 7 Bar (g).

SLIDE 9

After installing the C700 centac air compressor there are 2 important points to be expected
namely saving power and saving spare parts, why did I say saving spare parts? because the
more equipment that rotates, the greater the potential for damage.

The following is an estimate for saving power after the installation of the Centac C700
Compressor.

…
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SLIDE 10

When we are going to install an equipment, the first thing we have to do is design.
For the ploting area, we from the mechanical team held a discussion with the operational
team as the person in charge in the area, namely the gortap pack and also the electrical
team. The first choice we propose is beside Compressor no 6 precisely under the T / G MHI,
but the electrical team does not agree in that area, because there are cables in that area
which are very dangerous and should not be disturbed.

We propose a second option under the SGP T / G besides air compressor no 5. and all teams
agree in that area. Then we do the design for the piping arrangement including Suction line,
Discharge line and also tapping for the inlet and oulet water cooler compressor.
Then the civil team designs the foundation for the compressor in accordance with the
request.

SLIDE 11

After design is complete, the next stage is construction. The civil team built the foundation
in accordance with the design that was made, and our mechanical team placed the
compressor on top of the foundation then leveled the compressor so that the compressor's
position was flat from the front and sides. After the compressor leveling is complete, the
civil team fills the foundation with grouting cement.

Then we do the mechanical piping erection for the compressor in accordance with the
design that has been made, the work carried out at ASD 2019.

The electrical team provided a power cable for the starter unit and instruments to install the
instrument equipment on the compressor.
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SLIDE 12

In the pre-commissioning stage, we do cleaning for suction piping in order to avoid the least
material entering the compressor when the compressor is running. Next we did an un-
couple to do a solo motorbike run test, one of the objectives was to ensure the direction of
rotation of the motor in accordance with the equipment design. After the motorbike solo
run test was finished we did a couple again.

The instrument and automation team conducted functional tests on all system controls. And
also plan to squench all compressors.

SLIDE 13

At the commissioning stage an Unload test is performed on the compressor, after that a
load and performance test to atmosphere is performed. Then the compressor is connected
to the new system then a compressor start-up and the Centac C700 air compressor are
ready to be used for mill operations.

SLIDE 14

A solo motor run test is carried out to ascertain the condition of the motor's performance
before it is connected to its load, and also to ensure that the motor rotation is on demand.
One of the parameters seen is the temperature of the motor. Based on the results of tests
conducted, the motor performance is good, meaning that parameters fall into the specified
range. (attached data)

SLIDE 15

Unload condition compressors are with Valve inlet open 15% and bypass open 100%.
An unload test is carried out to determine the compressor's performance when the
compressor is not loaded, vibration parameters, temperature and pressure must be in
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normal condition before the load test is performed. A good performance is obtained,
according to the expected parameters. (attached data)

SLIDE 16

The compressor is carried out full load test to atmosphere with the condition of the inlet
valve open 100% and the bypass fully closed, aiming to determine the compressor's
performance at full load in accordance with the set point that has been entered. At the time
of the load test conducted on July 6, 2019 a compressor set point point of 5.70 Bar (g) was
entered. and the results are as expected. (attached data)

SLIDE 17 (Belum ada)

SLIDE 18 (Belum ada)

SLIDE 19 (Belum ada)

SLIDE 20

After the start-up process is complete, then we must take care of the compressor
periodically, by maintaining the following parameters, namely: We must replace the air filter
within 200 hours of operation and also we see a differential pressure of 0.3 Psi. between the
two references that we must act on is what happened first. We also have to do Oil Service
after 8000 hours, Oil Filter for 4000 hours, Oil mister 2000 hours and Motor Lubrication for
8000 hours.
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SLIDE 21

We also have to do condition monitoring of the compressor every day, that is checking the
water trap whether it is still working properly, the motor current, oil pressure, oil
temperature, vibration of each stage, and the temperature of each stage.

SLIDE 22

The next topic is about the summary of the second presentation of GT, I discussed the WTP
plant and Demin Plant. I discussed how the process of the water treatment plant and demin
plant, I also discussed the main equipment of the WTP and Demin Plant and the desired
parameters of each plant, there are some troubleshooting that I discussed, namely pump
speed is not right.

SLIDE 23

In my third presentation as a GT, I discussed Multi Fuel Boilers, namely Boilers with a
capacity of 200 T / H Pressure 84 Bar (g) and a temperature of 490 deg C, made by
autokumpu energy and using fuel, shells, caul, bark and oil.

I discussed the system contained in the Multifuel Boiler process and also its main
equipment, namely BFW pump, Feed water Deaerator tank, steam drum, primary and
secondary air fan and also Boiler Tube specifications.

I also discussed my activities during ASD 2019. Among them are Replace bottom floor mixing
tank demin plant, Install new compressor centac C700, and learning about capex pressure
part jobs.
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SLIDE 24

The next topic is about my daily activities, namely: maintaining good team work and
communication with operations, Instrument, Electrical, Civil, Workshop and safety.

I also created a list of equipment related to availability of spare materials, especially energy
areas, made reports for daily maintenance jobs, and also did some troubleshooting when
problems occurred in the area.

SLIDE 25

One of the troubleshooting that I will discuss is the Electrostatic Precipicator (ESP) ESP is a
tool that serves as a catcher of the ashes of combustion combustion in the boiler with a
capture efficiency above 90%.

SLIDE 26

Before troubleshooting, we must first comply with the working principles of ESP. there are
negative charged emitting plates and positively charged collecting plates. In MFB the
distance between DE and CE is 20 cm. When the neutral charged boiler ash passes through
the collecting plate, it becomes more negative because it gets negative ions from the
emiting plate and then the ash attaches to the positively charged collecting plate. Then the
ash attached to the collecting plate is dropped using the hummer system. Then the ash falls
into the esp hopper and is carried using a scrubber conveyor to fly ash.

SLIDE 27

For ESP RB equipment, the manufacturer uses FLS midth and MFB uses Tai & Chyun.

There are advantages and disadvantages of each ESP design equipment. for example
Discharge Electrode designs of different types, namely spikes and spirals. The advantage of
the spike model is that it is stronger and not easily broken, but the ash falls more easily due
to greater elongation.
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SLIDE 28

Here are the differences between the insulator of RB and MFB, where for RB use the
rapping insulator above and MFB uses the side model.

SLIDE 29

Troubleshooting ESP problems.

The case that I've solved is ESP MFB trip. The first thing we have to do is do an inspection on
the MCC together with the electrical team and try to turn on ESP, if it is successful, ESP will
On. Why do I say that, because according to the experience I did when the ESP 2 MFB trip, I
tried to turn it on at MCC and it turned out that Cell 1 ESP was successfully On, while Cell 2
ESP could not, with conditions kV <10 and mA 400.

If the voltage drops while the current rises, it identifies that: 1. Ash in the esp espers is full
and 2. There is a short in esp between the emiting and collecting plates.

First, we explore first the first potential, namely ash in the full ESP hopper, causing ESP to be
short.

SLIDE 30

First, we ascertain the ash condition in the ESP scrubber conveyor, if dust is empty it means
there is a problem.

After that we bypass the hummer hopper to continue to make sure the hopper is full or
empty. And also we make sure the vacuum is good by opening the check hole in the hopper.
If the vacuum is good, then we have to do an inspection into the ESP.

If the hopper plug up condition, we must un-plug, after that we try to restart ESP if it is
successful then ESP will start. If it fails, then we have to do an inspection into ESP.
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SLIDE 31

We do an internal inspection into ESP, first turn off ESP, lower the braker and turn off all
rapping systems, then close the inlet and outlet dumper so that it is safe to carry out
inspections inside the ESP. then open the ESP man hole and install the grounding.

Then do an inspection into the ESP according to the manufacturer's standard. Here are
some examples of internal inspection cases that I did. One of them is that the glue is
attached to the collecting plate because the lock of the emiting plate is broken, causing a
short ESP.

SLIDE 32

Make improvements to all findings, and also we must clean all ESP insulators. then release
the grounding, turn on all rapping systems and do an unload test on ESP, setting the
electrical side from small to large parameters. Perform an evaluation, hear spark sound
from outside and check the spark rate (spm) is normal or abnormal.

If successful, close the ESP man hole and open the ESP dumper inlet and outlet.

Monitor ESP temperature ie 110 - 135 deg C. then load ESP and make sure it is operating
normally.

SLIDE 33

Next I will discuss sootblower on Multifuel Boilers.

The operation of the sootblower equipment will increase the efficiency of the boilers.

Steam sootblower exhaled through the nozzles will clean the surface of the boiler heating
pipes from the dirt that sticks in so that the absorption of heat will return to maximum.

The MFB uses a fabric sootblower from Diamond Hubei. For rotary with G9B model and
retractable with IK-525 model.
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SLIDE 34

Abnormal conditions in the sootblower can cause the boiler tube to leak. So that the boiler
breaksdown.

A poppet valve that passes or does not work according to the mechanism and the position
of the nozzle from the sootblower leads directly to the boiler tube will erode the boiler
tube.

All we have to do is, conduct periodic inspections of the sootblower and make repairs.

SLIDE 35

Here are the ways we do to ensure the poppet valve does not pass. We periodically check
the temperature before and after the poppet valve. And do preventive maintenance of all
equipment on the sootblower, especially mechanical equipment.

SLIDE 36

The next topic is about improvement that I have done during the GT period at PT Toba Pulp
Lestari.

I am a member of Kaizen Reduce Energy Cost.

Also made 3 JDI with Title, provide safety guard condensate tank Demin Plant, Provide
stairway for safety access at the ESP MFB inlet damper manual, and Craeted checklist and
implement the inspection of all Energy Seal Energy Areas. For a more detailed explanation
of JDI, the data is attached.

SLIDE 37

In closing I quote a statement, "Burn your fear of failure with the fire of desire so that you
may open the door of success"

Thank you for your attention, I thank you. I return it to Mr. Zulfikar.