Field-Based Hydraulic Performance Audit of A Centrifugal Pump In A Fuel Distribution Terminal: Cavitation Assessment, Capacity Evaluation, and Variable Speed Drive Optimization

Abstract

Centrifugal pumps are the operational backbone of fuel distribution terminals, where unplanned downtime or hydraulic failure can cascade into critical supply chain disruptions affecting national energy logistics. Despite their strategic importance, site-specific hydraulic performance evaluations of fuel terminal pumping systems remain underrepresented in the literature, leaving operators reliant on design-stage assumptions rather than field-verified evidence for maintenance decisions and efficiency improvements. This study addresses that gap by conducting a comprehensive hydraulic performance audit of the MCPK 125-100-400 CC centrifugal pump operating within the fuel distribution system at PT Pertamina Patra Niaga Fuel Terminal Tegal, Indonesia. Field observations and operational data collection were performed to evaluate critical hydraulic parameters, including flow velocity, actual and design flow rates, Reynolds number, head loss distribution, Net Positive Suction Head Available (NPSHa), Net Positive Suction Head Required (NPSHr), and Bernoulli equation compliance across the suction and discharge lines. Results confirm that the pump delivers a capacity of 165 m³/h, exceeding the actual operational demand of 1,600 L/min and establishing an adequate reserve for uninterrupted truck loading operations. A calculated NPSHa of 5.23 m exceeds NPSHr of 2.64 m, demonstrating a positive cavitation safety margin of 2.59 m under current field conditions. While the discharge flow velocity of 5.6 m/s satisfies standard hydraulic design criteria, fixed-speed operation against fluctuating demand introduces measurable energy inefficiency. Integration of a Variable Speed Drive (VSD) is proposed as a targeted retrofit to align pump output with real-time demand, reduce energy consumption, and extend equipment service life. The hydraulic audit methodology presented here offers a replicable framework for performance-based pump evaluation in fuel distribution infrastructure.