The purpose of this reliability initiative was to identify and implement several specific upgrades that could be done simultaneously when a pump was removed to the shop for a repair. The number of modes that exceed their acceptable operating parameters often reduces the ideal interval between equipment repairs. However, in reality, pumps are momentarily run without product or operated with contaminated lubricant or reinstalled with oversize bearing housing bores, etc. Based on the common failure modes, several improvement programs were initiated at the Oakville facility. This article reviews these programs as applied to single stage centrifugal process pumps and their respective results, as well as the overall changes to the site reliability.
Successful programs require communication with all the various parties involved.
Trades personnel need to understand the current reliability status, why the programs are being initiated and the goals of said programs. The operations group and senior management must realize the benefits they might gain for the risks they might incur due to the length of time a pump is out of service for repair. Whichever group is responsible for equipment repair costs must know why costs might increase at the start of an improvement program, but will either remain the same or shrink as reliability is increased. Occasional unforeseen problems will arise no matter how well an improvement program is planned-everyone must realize this from the start. Once a program is initiated, ongoing communicataion and status updates are important.