APPROVAL

Title

: Operation and Maintenance of Centrifugal Pump

By

: Gilang Aditya

Name of Training

: Operator and Technician Training Program Batch 4

(Mechanical) TOTAL E&P INDONESIE.

This Paper has been approved in Cepu , July 2015

Approved by :

Advisor,

English Corrector,

(Totok Widiyanto M.T. )

NIP 196704201994031001

(Luita Yusniawati D, S.Pd.)

NIP 198306152008012019

Course Leader,

(Rinto Parnaedy A.Md)

NIP 197506182006041018

ACKNOWLEDGMENT
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 and Technician Training Program Batch 4 held
in PUSDIKLAT CEPU which took place on January 12, 2015 until July 14,
2015.On this occasion, I would like to thank :
1.
2.
3.
4.
5.
6.
7.
8.

The Management of Total E & P Indonesie.

The Management of Radiant Utama Interinsco, Tbk.
The Management PUSDIKLAT Cepu.
The Course leader Rinto Parnaedy A.Md.
The Adviser, Totok Widiyanto.
The English Corrector, Luita yusniawati D, S.Pd.
All Lecturers and Employees PUSDIKLAT Cepu Oil and Gas.
The father, mother, sister and my big family who have given prayers,
motivation and spirit for me.
9. All OTP 4 friends who always gives spirit and togetherness.
Given the limited time and the limitation of my knowledge, all the
criticism and suggestions for improvement individual paper is highly
expected. Hopefully this paper can be useful for me in particular and for
the general reader.
Cepu, July 2015

Gilang Aditya

ABSTRACT
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 add 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 operates in optimum performance.

TABLE OF CONTENTS

APPROVAL...................................................................................................i
ACKNOWLEDGMENT.................................................................................ii
ABSTRACT.................................................................................................iii
TABLE OF CONTENTS..............................................................................iv
LIST OF FIGURES......................................................................................vi
CHAPTER I..................................................................................................1
INTRODUCTION..........................................................................................1
I.1 Background.........................................................................................1
I.2 Objectives...........................................................................................2
I.3 Scope of Discussion...........................................................................2
I.4 Writing System....................................................................................2
CHAPTER II.................................................................................................3
BASIC TEORY.............................................................................................3
II.1 Definition of Pump.............................................................................3
II.2 Classification of Pump.......................................................................3
II.3 Basic Principle of Centrifugal Pump..................................................4
II.4 Type of Centrifugal Pump..................................................................5
II.5 Components Centrifugal Pump.........................................................6
II.5.1 Stationery Component.................................................................7
II.5.2 Rotary Component....................................................................10
II.6 System in Centrigugal Pump...........................................................13
II.6.1 Lubrication System....................................................................13
II.6.2 Cooling System.........................................................................13
II.6.3 Sealing system..........................................................................14
II.7 Advantages and Disadvantages of Centrifugal Pump.....................14
II.7.1 Advantages of Centrifugal Pump...............................................14
II.7.2 Disadvantages of Centrifugal Pump..........................................14
II.8 Safety Device...................................................................................15
CHAPTER III OPERATION AND MAINTENANCE OF CENTRIFUGAL
PUMP.........................................................................................................16

III.1 Operation......................................................................16
III.1.1 Pre-start Check.........................................................................16
III.1.2 Start up Procedure...................................................................17
III.1.3 Operation Condition checks.....................................................17
III.1.4 Stop Procedure.........................................................................18
III.1.5 Priming Centrifugal Pump........................................................18
III.2 Maintenance....................................................................................19
III.2.1 Preventive Maintenance...........................................................20
III.2.2 Predictive Maintenance............................................................22
III.2.3 Corrective Maintenance...........................................................23
III.2.4 Breakdown Maintenance..........................................................23
CHAPTER IV CONCLUSION...................................................................24
REFERENCES...........................................................................................25

LIST OF FIGURES
Figure 1 Positive Displacement Pump.........................................................3

Figure 2 Non Positive Displacement Pump..............................4

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 parts.
b. Uniformity of motion which is continuous with little or no periodic
c.
d.
e.
f.

variation in the rate of flow and pressure.

Great reliability of operation and easy to maintain.
Small size (due to their high speed), which mean require less room.
Self lubricating of the rubbing elements inside the pump by the liquid.
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.

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, pump system , general operation,

and maintenance of centrifugal pump.
I.4

Writing System

The writing system of this paper is :

a. Chapter I Introduction
This chapter explains about the background,objective,scope of
discussion 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 place to another place through a media of pipe (pipe line) by
increasing energy inside the liquid that is moved 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

Figure 1 Positive Displacement Pump

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
energy . In centrifugal pump, the energy results 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
throws 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 increases 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 :
a.

b.

c.

d.

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

e. Based orientation of case-split

Axial Split
Radial Split

f.

Based on bearing support

Figure 4 Pump Animation

II.5

Overhung

Between Bearing

Components of 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 5 Pump Animation. The main components are discussed in brief
below. Figure 6 Pump in the field shows these parts on a photograph of a
pump in the field.

Figure 5 Pump Animation

Figure 6 Pump in The Field

II.5.1 Stationary Components

Stationery Component at centrifugal pump consists of :
a. Base plate and frame
The function of base plate and frame is to support pump. For pump that
directs coupled with prime mover , the pump and prime mover sited in one
base plate or frame
b. Casing
Casing has many functions as follows:

Protecting all rotating part

Mounting of guide vane and diffuser,inlet and outlet nozzle
Having place that gives the direction of flow of the impeller and convert
the fluid velocity energy into dynamic energy (single stage).

Figure 7 Casing

c. Diffuser
Diffuser is 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.

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
decrease 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.

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 consists 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
From the impeller hub , the vanes extend radialy, without shrouds 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 plates 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

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

c. Shaft Sleeve
The functions of shaft sleeve,there are:
1) To protect the shaft from erosion , corrosion,wear and tear on the
stuffing box.
2) To be prevent leakage , internal bearing and interstage or distance
sleeve.

Figure 12 Shaft Sleeve

d. Bearing
The functions 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.
3) To keep the rotating shaft and impeller in correct position within the
stationary parts of the pump.Pump bearings can be divided 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,...), It 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..
b. Oil lubrication is the most common on process pumps.
Various lubrication systems are used:
Oil bath
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 are :

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.
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 indicator a condition of
pump and keep a pump running in optimum condition.The following safety
device are generally used with pumps, and more specifically with
centrifugal pumps:
a. A low-pressure suction transmitter (protection against cavitation),
b. A high-pressure outlet transmitter,

c. A temperature sensor on the pump body if

necessary,
d. A temperature sensor on the bearings,
e. A vibration sensor,
f. Leak protection on the packing.

CHAPTER III
OPERATION AND MAINTENANCE
OF CENTRIFUGAL PUMP

III.1 Operation
All provision to operate the should pump follow the instruction from
pump the manufacturer 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 steps 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 procedures to pre-check before the operation:
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 be 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
c.
d.
e.
f.

low speed then increase slowly until it 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.

III.1.3 Operation Condition Checks

a. Check the variable operation like pressure, temperature, flow rate and
prime mover rpm.
b. Manometer and amperemeter 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.

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

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 cavitation, 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.
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 wearing 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
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 prevention.
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, bad bearing or some abnormal condition.
d.flow
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

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.

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
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 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

REFERENCES
Sandjojo. Basic Mechanical Operation Maintenance And Troubleshooting
Handoko,Susilo.Pumps : Pusdiklat Migas Cepu
Adjie, Ilham Dwipraptomo. Operation, Maintenance And Troubleshooting
of Centrifugal Pump. Cepu:Pusdiklat Migas
PUMP.exp-pr-eq070-en Total E&P Indonesia
PUMP MAINT.exp-sm110-en Total E&P Indonesia
http://mechanic-mechanicalengineering.blogspot.com/2011/03/pompapump.html (20-06-2015)