Best Practices - Pump Reliability

Synchronous is all about operational excellence for the process industry. In the process industry, we tend to have a large investment in pumps of all sizes, shapes and types. Pumps are a big component of our maintenance budget as well. Are there best practices to help us protect our capital investment in pumps, and to optimize our pump maintenance cost? You bet, and we would propose the following as a starting point:

- Establish operator tours on each shift to inspect and log pressure gauges, leaks, lubrication levels, unusual noises (ie cavitation) and report this information.

- Develop a detailed pump start up and operation procedure. Operators need to have an understanding of pump operating principles to help maintenance keep them in service.

- Develop an in-line spare pump policy. Critical pumps need to have installed, in-line spares. Considerations include effect on production downtime, ease of changeover, ease of of access and detecting operating problems, local environmental conditions, and historical records of pump reliability. When in-line spare pumps are used, consideration should be given to ensure their reliability when needed - preventive maintenance servicing, etc.

- Maintenance and the pump repair shop has a big role to play as well. Work flows and tools should be highly organized, and clean. Instill better repair standards, craftsmanship, and dedicate a "clean" room for precision repairs.

- Establish precision standards for balancing, lubrication, seals, vibration isolators, foundations, installation and start-up, shaft precision, and alignment. Have a written checklist for each pump and keep excellent records.

Synchronous LLC is committed to maintaining a continuing dialogue on operational excellence and best practices for the process manufacturing industry. To pose a question, contribute a best practice, or otherwise add to the dialogue, send a note to RobBaldwin@SynchronousLLC.com . To subscribe to our weekly newsletter send your preferred email contact address to Webmaster@SynchronousLLC.com with SUBSCRIBE in the subject line.