APPROVAL

Title : Operation and Maintenance of Centrifugal PumpBy : Gilang AdityaName 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. ) (Luita Yusniawati D, S.Pd.) NIP 196704201994031001 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. The Management of Total E & P Indonesie.2. The Management of Radiant Utama Interinsco, Tbk.3. The Management PUSDIKLAT Cepu.4. The Course leader Rinto Parnaedy A.Md.5. The Adviser, Totok Widiyanto.6. The English Corrector, Luita yusniawati D, S.Pd.7. All Lecturers and Employees PUSDIKLAT Cepu Oil and Gas.8. 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

ABSTRACTIn 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

APPROVALiACKNOWLEDGMENTiiABSTRACTiiiTABLE OF CONTENTSivLIST OF FIGURESviCHAPTER I1INTRODUCTION1I.1 Background1I.2 Objectives2I.3 Scope of Discussion2I.4 Writing System2CHAPTER II3BASIC TEORY3II.1 Definition of Pump3II.2 Classification of Pump3II.3 Basic Principle of Centrifugal Pump4II.4 Type of Centrifugal Pump5II.5 Components Centrifugal Pump6II.5.1 Stationery Component7II.5.2 Rotary Component10II.6 System in Centrigugal Pump13II.6.1 Lubrication System13II.6.2 Cooling System13II.6.3 Sealing system14II.7 Advantages and Disadvantages of Centrifugal Pump14II.7.1 Advantages of Centrifugal Pump14II.7.2 Disadvantages of Centrifugal Pump.14II.8 Safety Device15CHAPTER III OPERATION AND MAINTENANCE OF CENTRIFUGAL PUMP16III.1 Operation16III.1.1 Pre-start Check16III.1.2 Start up Procedure17III.1.3 Operation Condition checks17III.1.4 Stop Procedure18III.1.5 Priming Centrifugal Pump18III.2 Maintenance19III.2.1 Preventive Maintenance20III.2.2 Predictive Maintenance22III.2.3 Corrective Maintenance23III.2.4 Breakdown Maintenance23CHAPTER IV CONCLUSION24REFERENCES25

LIST OF FIGURES

Figure 1 Positive Displacement Pump3Figure 2 Non Positive Displacement Pump4Figure 3 Centrifugal Pump5Figure 4 Pump Animation5Figure 5 Pump Animation6Figure 6 Pump in The Field7Figure 7 Casing8Figure 8 Diffuser8Figure 9 Stuffing Box9Figure 10 Wearing Ring9Figure 11 Types of Impeller11Figure 12 Shaft Sleeve12Figure 13 Ball and sleeve Bearing12

i

iii

CHAPTER IINTRODUCTION

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 periodicvariation in the rate of flow and pressure.c. Great reliability of operation and easy to maintain.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.

I.2ObjectivesThe 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 DiscussionThis paper is focused on basic principle, pump system , general operation, and maintenance of centrifugal pump.I.4 Writing SystemThe 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 TheoryThis 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 ConclusionThis Chapter explains about the conclusion of this paper based on the operation and maintenance of centrifugal pump.

CHAPTER IIBASIC TEORY

II.1 Definition of PumpPump 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.3Basic 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.4Type of Centrifugal Pump

Centrifugal pump can be classified based on :a. Based on flow Axial Flow Radial Flow Mixed Flowb. Based on stage Single Stage Multi stagec. Based on suction side of impeller Single Suction Double Suctiond. Based on shaft positionFigure 4 Pump Animation

Horizontal Shaft Vertical Shaft

e. Based orientation of case-split Axial Split Radial Splitf. Based on bearing support Overhung Between Bearing

II.5 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.5.1Stationary ComponentsStationery Component at centrifugal pump consists of :a. Base plate and frameThe function of base plate and frame is to support pump. For pump thatdirects coupled with prime mover , the pump and prime mover sited in one base plate or frame

b. CasingCasing 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 Casingc. 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 BoxStuffing Box serves to prevent leaks in the area where the shaft penetrates the pump casing.Figure 9 Stuffing Box

e. Wearing RingWearing 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 on1) Type of liquid handled.2) Difference pressure that passes through the clearance between rings.3) Critical velocity.

II.5.2Rotary ComponentRotary component at centrifugal pump consists of :a. ImpellerImpeller 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 ImpellerFrom 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 impellerVanes 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 Impellerb. ShaftShaft 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 SleeveThe 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 Sleeved. BearingThe 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.6System in Centrigugal Pump

II.6.1Lubrication 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 circulationII.6.2Cooling SystemIf 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.6.3Sealing systemA 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 : Static seal: O-Ring and Gasket Dynamic: Mechanical Packing and Mechanical Seal

II.7Advantages 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.7.2Disadvantages of Centrifugal Pump. High viscous liquids are not handled well. They are not self priming. Cant produce high pressure..

II.8 Safety DeviceSafety 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 IIIOPERATION AND MAINTENANCEOF CENTRIFUGAL PUMP

III.1 OperationAll 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. Pre-checked before operationb. Start up procedurec. Operation condition checksd. Stop Procedure

III.1.1 Pre-start CheckIt 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 smoothf. 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 ProcedureThere 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 speed then increase slowly until it reaches the normal speed.c. Wait for a while until it reaches normal pressure.d. Open the discharge valve slowly until normal condition operation.e. Check the critical part.f. If there is an abnormal condition like sound or vibration, stop the prime mover then check again for troubleshooting.

III.1.3Operation Condition Checksa. 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 Procedurea. 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.1.5Priming Centrifugal PumpUnlike 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 MaintenanceMaintenance 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. Optimum operating condition b. Prevent severe damage suddenlyc. Maximum utilization of maintenance resourced. Extend the life of the pumpe. Minimum spares inventory

The kinds of maintenance of centrifugal pump area. Preventive maintenanceb. Predictive maintenancec. Corrective maintenanced. 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 inspectionThere 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 inspection1) 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 inspection1) 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 inspection1) 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 motorf.OverhaulFor 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 testedIII.2.2 Predictive MaintenancePredictive 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 inspectionIt is done in multiple locations in the system to indicate that a failure has already started.b. Heat thermal checkIt is usually checked in the seal chamber and bearing wear and bearing case.c. Noise inspectionIt is to indicate cavitation, bad bearing or some abnormal condition.d.flowIt supposes check the status of wearing ringe. Leakage and fugitive emissionsIt is done to check the seal performance in both the stufing box and bearing case location.f. Power consumptionIt is done to check the efficiency of pump.III.2.3 Corrective MaintenanceCorrective 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 MaintenanceThe 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.

CHAPTER IVCONCLUSIONCentrifugal 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 conditionb. Maximum utilization of maintenance resourcec. Optimum equipment lifed. Minimum spares inventory

REFERENCES

Sandjojo. Basic Mechanical Operation Maintenance And TroubleshootingHandoko,Susilo.Pumps : Pusdiklat Migas CepuAdjie, 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 Indonesiahttp://mechanic-mechanicalengineering.blogspot.com/2011/03/pompa-pump.html (20-06-2015)