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TOTAL E & P INDONESIE

APPROVAL SHEET
Title

: Operation And Maintenance Of Centrifugal Pump

By

: Gilang Aditya

Name of Training

: Operator Technician Program Batch 3 (Mechanical) Total

E&P Indonesie

This Work Paper has been approved in ..(month). 2015

Approved by :

Advisor,

English Corrector,

( Totok Widiyanto )
NIP 196704201994031001

(Luita yusniawati D, S.Pd.)


NIP 198306152008012019

Course Leader,

(Rinto Parnaedy A.Md)


NIP 197506182006041018

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PREFACE
All praise and gratitude for the presence of GOD Almighty who has
given of gifts and blessings, so that Paper entitled "Centrifugal Compressor
System" can be finished. Composing this paper is one part of a whole series of
activities held by Total E & P Indonesie on education and training programs
Operator Training Program Batch 4 held in Cepu Oil and Gas PUSDIKLAT
which took place on January 12, 2015 until July 14, 2015.On this occasion, I
would like to thank :
1. The father, mother, sister and my big family who have given prayers,
motivation and spirit for me.
2. The Management of Total E & P Indonesie.
3. The Management of Radiant Utama Interinsco, Tbk.
4. Leaders PUSDIKLAT Cepu Oil and Gas.
5. Course leader Rinto Parnaedy A.Md.
6. Adviser, Totok Widiyanto.
7. English Corrector, Luita yusniawati D, S.Pd.
8. All Lecturers and Employees PUSDIKLAT Cepu Oil and Gas.
9. All OTP 4 friends who always gives spirit and togetherness.
Given the limited time and the preparation of my knowledge, all the criticism
And suggestions for improvement Individual Working Paper is highly expected.
Hopefully this paper can be useful for me in particular and for the general
reader.
Cepu, juli 2015

Gilang Aditya

ABSTRACT

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In petroleum industry, the pump has an


important function in supporting oil production. The
existence

of

pump

is

absolutely

needed.

Oil

moving

can

be handled by pump. Centrifugal is one kind off non-positive displacement


pumps, which uses impeller to move liquid and adds the energy into liquid flow
in pipelines.
In the operation of centrifugal pump,we can arrange in series or parallel.
The series operation is used to get high pressure (head), and parallel series
to get to get high capacity.
Right step of the operation will prevent the equipment from damage. The
basic centrifugal maintenance like preventive, predictive, corrective and
breakdown maintenances and the troubleshooting in centrifugal is also needed
to keep equipment operate in optimum performance.

TABLE OF CONTENTS
APPROVAL SHEET i

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PREFACE

ii

ABSTRACT iii
TABLE OF CONTENTS

iv

LIST OF FIGURES vi
CHAPTER I INTRODUCTION
1.1Background

1.2 Objectives

1.3 Scope of Discussion

1.4 Writing system 2


CHAPTER II BASIC THEORY
2.1 Definition of Pump

3
3

2.2 Classification of Pump 3


2.3 Basic Principle of Centrifugal Pump 4
2.4 Type of Centrifugal Pump

2.5 Components Centrifugal Pump

2.6 System in Centrifugal Pump 13


2.7 Advantages and Disadvantages of Centrifugal Pump
2.8 Safety Device in Centrifugal Pump

14

15

CHAPTER III OPERATION,MAINTENANCE AND TROUBLESHOOTING OF


CENTRIFUGAL PUMP
16
3.1 Operation

16

3.1.1 Pre-start check

16

3.1.2 Start-up procedure

17

3.1.3 Operation condition checks 18


3.1.4 Stop procedure

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3.1.5 Priming centrifugal pump


3.2 Maintenance

19

3.2.1 Preventive maintenance

20

3.2.2 Predictive maintenance

22

3.2.3 Corrective maintenance

23

3.2.4 Breakdown maintenance

23

CHAPTER IV CONCLUSION
REFERENCES

18

25

26

LIST OF FIGURES
Figure 1 Positive Displacement Pump.................................................................3
Figure 2 Non Positive Displacement Pump.........................................................4

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Figure 3 Centrifugal Pump.............................................................5


Figure 4 Pump Animation...............................................................5
Figure 5 Pump Animation....................................................................................6
Figure 6 Pump in The Field.................................................................................7
Figure 7 Casing....................................................................................................8
Figure 8 Diffuser..................................................................................................8
Figure 9 Stuffing Box...........................................................................................9
Figure 10 Wearing ring........................................................................................9
Figure 11 Types of Impeller................................................................................11
Figure 12 Shaft Sleeve......................................................................................12
Figure 13 Ball and sleeve Bearing.....................................................................12

CHAPTER I
INTRODUCTION
I.1 Background
Pumps are equipment that is widely used in oil and gas company, to
support a process and to transfer a liquid through the pipeline. There are many
kinds of pumps types available. A centrifugal pump is the most common used
than other. Several reasons of a centrifugal pump to become mostly used in oil
and gas company are:

a. Centrifugal pump relatively has a simple construction because it has


less moving
b. Uniformity of motion which is continuous with little or no periodic
variation in the rate of flow and pressure
c. Great reliability of operation and easy to maintain

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d. Small size (due to their high speed), which mean


require less room
e. Self lubricating of the rubbing elements inside the pump by the liquid
f. Low investment and maintenance cost for high capacity pumping

During the operation of centrifugal pump, it is important to maintain


reliability of pump in order to get the optimum operation result. So, the pump
maintenance strategy must plan not only for keeping the equipment in optimum
reliability but also getting the effective and efficient way for maintenance. Good
maintenance will increase life time of equipment and prevent it from
breakdown.
Many cases happen while the centrifugal pump.
I.2

Objectives

The objectives of this paper are :


a.To describe the working principle of centrifugal pump.
b.To know the basic operation of centrifugal pump.
c.To know the maintenance of centrifugal pump.

I.3

Scope of Discussion

This paper is focused on basic principle, system in pump, general operation,


and maintenance of centrifugal pump.
I.4

Writing System

The writing system this paper is :


a. Chapter I Introduction
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This

chapter

explains

about

the

background,objective,limitation and the writing


system of this paper.
b. Chapter II Basic Theory
This Chapter explains about basic principle, main components, system and
the advantages and disadvantages of centrifugal pump.
c. Chapter III Operation and Maintenance of Centrifugal Pump.
This Chapter explains about the right way of operation and maintenance of
Centrifugal Pump.
d. Chapter IV Conclusion
This Chapter explains about the conclusion of this paper based on the
operation and maintenance of centrifugal pump.

CHAPTER II
BASIC TEORY
II.1

Definition of Pump
Pump is a rotating machine that is used to move liquid from one
palce to another place through a media of pipe (pipe line) by increasing
energy inside the liquid that is moved and happens continuously.
Centrifugal pump is a kind of pump which works by changing the
kinetic energy (velocity) of the liquid into potential energy (pressure) by
the casing shape (volute) or diffuser.

II.2

Classification of Pump

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Figure 1 Positive Displacement Pump

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Figure 2 Non Positive Displacement Pump

II.3

Basic Principle of Centrifugal Pump


Centrifugal pump is one type of pump that increases the energy of
liquid by converting the kinetic energy to the pressure.In centrifugal
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pump, the energy result from rotation of


impeller,energy from the prime mover is used
by the shaft to rotate the impeller, the rotation of impeller causes the
centrifugal force. The centrifugal force makes the liquid coming from the
eye of impeller which is sited in the cavity between the vane rotate then
throw out by the centrifugal force into the radial direction. In the
impeller ,the velocity of liquid increases.The liquid throws out into the
volute casing, as the liquid enters the volute, the velocity decreases then
it is converted into pressure energy.
The Impeller increase the velocity of the liquid then it is converted
by the volute casing into the pressure energy , it means that the
differential pressure developed across the Centrifugal pump is the result
of converting the kinetic energy into the pressure energy not by the
changing the volume.

Figure 3 Centrifugal Pump

II.4

Type of Centrifugal Pump


Centrifugal pump can be classified based on :

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b.

c.

d.

e.

f.

II.5

a. Based on flow
Axial Flow
Radial Flow
Mixed Flow
Based on stage
Single Stage
Multi stage
Based on suction side of impeller
Single Suction
Double Suction
Based on shaft position
Horizontal Shaft
Vertical Shaft
Based orientation of case-split
Axial Split
Radial Split
Based on bearing support
Overhung
Between Bearing

Components Centrifugal Pump


A centrifugal pump has two main components :

a.

A stationary component (static part)

b.

A rotating component (dynamic part)

The general components, both stationary and rotary, are depicted in Figure
Pump Animation. The main components are discussed in brief below. Figure
Pump in the field shows these parts on a photograph of a pump in the field.

Figure
Figure 45 Pump
Pump Animation
Animation

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Figure 6 Pump in The Field

2.5.1 Stationery Component


Stationery Component at centrifugal pump consist of :

a. Base plate and frame


The function of base plate and frame is to support pump. For pump that
direct coupled with prime mover , the pump and prime mover sited in one base
plate or frame
b. Casing
Casing has many functions as follows:
To protect all rotating part

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Mounting of guide vane and diffuser,inlet and outlet


nozzle
Place that gives the direction of flow of the impeller and the fluid velocity
convert energy into dynamic energy (single stage).

Figure 7 Casing

c. Diffuser
Diffuser used for regulate flow of liquid to volute space (for single stage) , or to
next stage (for multistage pump), and change kinetic energy into potential
energy.

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Figure 8 Diffuser

d. Stuffing Box
Stuffing Box serves to prevent leaks in the area where the shaft penetrates the
pump casing.

Figure 9 Stuffing Box

e. Wearing ring
Wearing ring is mounted in casing and impeller. The main function is to
decreasing the leakage of liquid through the front and behind impeller.It works
by decreasing the clearance between casing and impeller.This ring is relatively
economically because it could replaced with the new one or repaired when it is
broken.

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Figure 10 Wearing ring

The types and construction of wearing ring depend on


1) Type of liquid handled.
2) Difference pressure that passes through the clearance between rings.
3) Critical velocity.

II.5.2 Rotary Component


Rotary component at centrifugal pump consist of :
a. Impeller
Impeller is the main components of centrifugal pump. It provides an extra
energy into liquid as kinetic energy.
There are three types of impeller used in centrifugal pump:
1) Open Impeller

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From the impeller hub , the vanes extend radialy,


without shrounds or cover plates.it has worst
efficiencies than the other types and it is suitable for liquid containing a lot of
scale.
2) Semi Closed impeller
Vanes extend radially from the hub,but one side has a cover plate. It has
middle efficiencies and it is suitable for pumping liquid that contains a lot of
scales.

3) Closed Impeller
From the impeller hub, the vanes radial extends with cover plates.The
vanes between two plate are joined as one units.This impeller has better
efficiencies than the other types and suitable for pumping clean liquid or that
containing a few scales.

Figure 11 Types of Impeller

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b. Shaft
Shaft has several function ,such as:
1) To forward torque of the prime mover for the pump operates.
2) Continuing power of the motor.
3) As mounting all rotating components

c. Shaft Sleeve
The function of shaft sleeve,there are:
1)

To protect the shaft from erosion , corrosion,wear and tear on the stuffing

box.
2)

As a joint leakage , internal bearing and interstage or distance sleeve.

Figure 12 Shaft Sleeve

d. Bearing
The function of the bearing of a centrifugal pump are:
1) To support the shaft carrying one more impellers.
2) To allow the shaft to rotate with a minimum of friction.

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3) To keep the rotating shaft and impeller in correct


position

within

the

stationary

parts

of

the

pump.Pump bearings can be devided into two basic types: Sleeve and shell
bearings, and ball and roller bearings.

Figure 13 Ball and sleeve Bearing

II.6

System in Centrigugal

Pump
II.6.1 Lubrication System

Any rotating mechanical component need a lubrication , (ball bearing,


roller bearing, bearing bush...), requires appropriate lubrication in order to
work properly.
Otherwise, overheating, excessive wear, seizing and even locking will
occur.
There are two distinct types of lubricants: grease and oil.
a. Grease lubrication is reserved for bearings. It is used for low power
pumps. Grease consumption is very low, but it needs to be topped up
from time to time. Any excess grease (balling) leads to overheating
which may cause deterioration.
b. Oil lubrication is the most common on process pumps.
Various lubrication systems are used:
Oil bath
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Forced circulation

II.6.2 Cooling System


If the pumped product is warm, it may be necessary to:

Cool the packing body.


Cool the bearing housing.
Cool the base .
Cool the sealing liquid.

II.6.3 Sealing system


A pumps function is to raise the pressure of a liquid. The
pressurised liquid contained in the pump may leak to the atmosphere
along the shaft. This leak will be eliminated or reduced using static seal
or dynamic seal.
Types of sealing are commonly used in centrifugal pump is:

II.7

Static seal
Dynamic

: O-Ring and Gasket


: Mechanical Packing and Mechanical Seal

Advantages and Disadvantages of Centrifugal Pump

II.7.1 Advantages of Centrifugal Pump

Its flow is continuously.


They dont require any valves.
Quiet operations.
They have relatively small space and weight requirements in relation to

throughput.
Low investment and maintenance cost for high capacity pumping.
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Stable and high flowrate.

II.7.2 Disadvantages of Centrifugal Pump.


High viscous liquids are not handled well.
They are not self priming.
Cant produce high pressure..
II.8 Safety Device
safety device in centrifugal pump aims for give indikator a condition of pump
and keep a pump running in optimum condition.The following safety equipment
is generally used with pumps, and more specifically with centrifugal pumps:
a.
b.
c.
d.
e.
f.

A low-pressure suction transmitter (protection against cavitation),


A high-pressure outlet transmitter,
A temperature sensor on the pump body if necessary,
A temperature sensor on the bearings,
A vibration sensor,
Leak protection on the packing,

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CHAPTER III
OPERATION AND MAINTENANCE
OF CENTRIFUGAL PUMP

III.1 Operation
All provision to operate the could follow the instruction from pump the
manufactured or from the SOP (Standard operating Procedure) which is made
based on the condition of operation.
Incorrect operation of centrifugal pump could result pump damage
downtime and avoidable repair work. There are several step in procedure to
operate the centrifugal pump:
a.
b.
c.
d.

Pre-checked before operation


Start up procedure
operation condition checks
Stop Procedure

III.1.1 Pre-start check


It is necessary to check the pump before starting the pump, there are several
procedure to pre-check before the operation:

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a. Check suction line and reservoir : There will be a


problem when reservoir and suction line are
clogged. Special attention is necessary to the pump that uses mechanical
seal.
b. Check electrical installation: check the electrical lines, circuit breaker and
cable connection.
c. Check the alignment: alignment of pump shaft and the prime mover shaft
should be checked to avoid vibrations and shaft deflection.
d. Check the lubricating oil: make sure that the lubricating oil and grease are
enough in quantity and good conditions.
e. Shaft rotation check: the shaft can be rotated by hand and the rotation is
smooth
f. Check the direction of rotation: make sure the direction of the pump rotation
is the same as the direction of prime mover rotation.
g. Discharge valve handling: in centrifugal pump the discharge valve should
be closed before the start up.
h. Priming: the centrifugal pump should primed before starting the pump, it is
done by filling the suction line until full with liquid and no air trapped.
i. Check the auxiliary equipment.

III.1.2 Start up procedure


There are several general steps to start up centrifugal pump:
a. Open the suction valve slowly until it is fully open.
b. Start the prime mover, if it is included variable speed drive, start with low
c.
d.
e.
f.

speed then increase slowly until its reaches the normal speed.
Wait for a while until it reaches normal pressure.
Open the discharge valve slowly until normal condition operation.
Check the critical part.
If there is an abnormal condition like sound or vibration, stop the prime
mover then check again for troubleshooting.

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III.1.3 Operation condition checks


a. Check the variable operation like pressure, temperature, flow rate and
prime mover rpm.
b. Manometer and ampere meter observation: the suction and the discharge
pressure should be the same as calculated pressure before and could not
be fluctuated. The ampere consumed by the pump should be under or less
than ampere specification at motor name plate.If the ampere is fluctuated, it
means any problems occur at the pump.
c. Vibration and noise check: make sure there is no over vibration from the
pump, use vibrometer for accurate vibration measurement. When noise and
over vibration appear, it means some components are in trouble.
d. Check the cooler and the cooling system.
e. Check lubricant and lubricating system.
f. Leakage check: normal condition happens if there is no leakage detected
by naked eyes view.

III.1.4 Stop procedure


a. Fully closed the discharge valve.
b. Stop the prime mover, if it uses variable speed control, decrease the speed
until it stop.
c. Fully closed the suction valve.

III.1.5 Priming centrifugal pump


Unlike the displacement pump, centrifugal pump cannot start and prime
it self. So before operating the centrifugal pump, it needs to be primed.

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When a pump is first put into service, its


passageways are filled with air. If the suction supply
is above atmospheric pressure, this air will be trapped in the pump and
compressed when the suction valve is opened.The purpose of priming is
accomplished by venting the entrapped air out of the pump through a valve
provided.

III.2 Maintenance

Maintenance is the act of the maintaining or the state of being maintained and
to keep something in proper condition. It is very important to prevent serious
damage from the operation of pump, a good maintenance could detect
abnormal condition early to avoid further damage. The purposes of
maintenance are :
a.
b.
c.
d.
e.

Optimum operating condition


Prevent severe damage suddenly
Maximum utilization of maintenance resource
Extend the life of the pump
Minimum spares inventory

The kinds of maintenance of centrifugal pump are


a. Preventive maintenance
b. Predictive maintenance
c. Corrective maintenance
d. Break down maintenance

III.2.1 Preventive maintenance


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Preventive maintenance tasks are intended to prevent unscheduled downtime


and premature equipment damage that will result in corrective or repair
activities. Preventive maintenance is managed based on time. It is usually
called time based maintenance. Generally, preventive maintenance of
centrifugal pump consists of:
a. Daily inspection
There are several activities of daily inspection for centrifugal pump:
1) Check temperature of stuffing box and pump casing that is still permitted is
not more than 30oc pumped liquid temperature.
2) Suction pressure and discharge pressure (indication at manometer should
be read), The discharge pressure and the suction pressure must be appropriate
or approach the fixed value before and should not be fluctuated abnormally. If
there is a strange material clogged the pump, there is air binding or capitation,
the pressure will drop or be fluctuated abnormally.
3) Check leakage from packing (visual inspection)
4) The leakage from stuffing box must drop the liquid whose the amount is not
more than 0.5 cm3/s (but if mechanical seal is used, it is forbidden to leakage)
5) Electrical current (indication at ampere meter). The electrical current that is
used must be lower than nominal value at name plate.
7) Check oil lubrication level at the stuffing box and rotation of oil ring.

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8) The lubricating oil should be checked and the oil


ring must be able to rotate normally.
9) Check and tighten bolt and nut and other joint connected with pump.

b. Monthly inspection.
1) Check the bearing temperature and check the temperature that is required, if
any trouble occurs, check them immediately.
2) Check the alignment between the pump shaft and the motor shaft.

c. 3- Monthly inspection
1) Oil change in the stuffing box, bearings.
2) Grease inspection (should be changed if worsen)
3) Check and maintain wearing ring impeller tolerance with ring casing.

d. 6- Monthly inspection
1) Check packing and shaft sleeve, if there is a scratch because of wearing out,
packing and shaft sleeve should be changed.
2) Check condition between pump shaft and prime mover shaft. If the
alignment shows deviation out of specification, it should be realigned.
e. Annually inspection
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1) Check the corrosion of the pump part that moves


or rotates, especially the clearance at the wearing
ring.
2) Check the corrosion inside of the pump casing,if needed, check thickness
for the preventing.
4) Check alignment of the pump shaft when the pump has been disassembled.
5) Check isolation of the motor
f.Overhaul
For overhaul, it is needed to open up the pump, check the pump part, repair or
exchange the pump part and reinstall the pump by following the guidance and
the procedure from manufacture, after that the pump needs to be tested
III.2.2 Predictive maintenance
Predictive maintenance is managed based on condition monitoring (condition
based maintenance). By condition check, we can know the process condition
and failure signs in operation condition. The predictive maintenance includes:
a. Vibration inspection
It is done in multiple locations in the system to indicate that a failure has
already started.
b. Heat thermal check
It is usually checked in the seal chamber and bearing wear and bearing case.
c. Noise inspection
It is to indicate cavitation, rubbing, bad bearing or some abnormal condition.
d.flow

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It supposes check the status of wearing ring


e. Leakage and fugitive emissions
It is done to check the seal performance in both the stufing box and bearing
case location.
f. Power consumption
It is done to check the efficiency of pump.
III.2.3 Corrective maintenance
Corrective maintenance is improvement about equipment condition The
improvement is done for modification. It is mostly important in order to get the
better maintenance based on experience of equipment.
III.2.4 Breakdown maintenance
The basic philosophy behind the breakdown maintenance is to

allow the

machine to run to failure and only repair or replace damage equipment just
before the equipment comes to a complete stop.Breakdown condition is the
maximum of engine operation limit. According to production and efficiency
demand, the breakdown maintenance is not longer chosen. Time frame of
production process that causes unavailable device will make product quality
decreasing.

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CHAPTER IV
CONCLUSION
Centrifugal pump is one of the equipment that is usually used in oil and
gas company. Its purpose is to move the liquid from one place to other place.
The principal work of centrifugal pump is to convert energy of a prime mover (a
electric motor or turbine) first into velocity or kinetic energy and then into
pressure energy of a fluid that is being pumped. The energy energy changes
occur by virtue of two main parts of the pump. They are the impeller and the
volute or diffuser. The impeller is the rotating part that converts fluid energy into

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the kinetic energy. The volute or diffuser is the


stationary part that converts the kinetic energy into
pressure energy.
To operate centrifugal pump besides we must follow the SOP (standard
Operating Procedure), we must prepare pump condition and check system of
pump (lubrication, cooling, vibration, etc). There are two kinds of operation
systems in centrifugal pump. First is series operation to gain more head
(pressure) and the second is parallel operation to gain more capacity (debit)
To maintain condition of centrifugal pump at optimum performance, a
good maintenance is needed. There are several kinds of maintenance that are
usually used in centrifugal pump. They are preventive maintenance, predictive
maintenance corrective maintenance, and breakdown maintenance. The
purposes of maintenance are :
a. Optimum operating condition
b. Maximum utilization of maintenance resource
C. Optimum equipment life
d. Minimum spares inventory
e. Optimum avaibility

REFERENCES

Sandjojo. Basic Mechanical Operation Maintenance And Troubleshooting


Handoko,Susilo.Pumps : Pusdikalat Migas Cepu
Adjie, Ilham Dwipraptomo. Operation, Maintenance And Troubleshooting of
Centrifugal Pump. Cepu:Pusdiklat Migas
PUMP.exp-pr-eq070-en Total E&P Indonesia

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PUMP MAINT.exp-sm110-en Total E&P Indonesia


http://mechanic-mechanicalengineering.blogspot.com/2011/03/pompapump.html (20-06-2015)

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