CHALLENGES
A coal process plant experienced significant plant downtime due to failures in the vacuum pump system, including motor trips, early hour failed components, and low vacuum.
PROCESS
We conducted a Root Cause Analysis (RCA) using Fault Tree
methodology to identify the appropriate failure modes. This included
running workshops with the appropriate stakeholders, analyzing
process and maintenance data, conducting field reviews and
consulting best practices. Once improvements were identified,
upgrades were specified and the execution was managed.
- Failure Analysis
- Project Management
- Workshop Facilitation
KEY METRICS
Based on the execution of the
identified recommendations, the following benefits were realized:
$20M
Savings per year due to decreased downtime.
80%
Reduction in water usage
ACTIONS
- Increased motor sizing to provide adequate horsepower.
- Installed sensors to properly monitor flow.
- Improved control system to regulate flow of seal water, and changed operating set points.
- Installed new rebuilt vacuum pumps due to worn components.
- Developed and trained operators on troubleshooting decision matrix.
- Improved preventative maintenance program to include internal inspections and component changeouts.
OUTCOMES
Decreased Plant Downtime
Plant downtime due to vacuum pump failure decreased from 18.5 hours/year to 0.
Decreased Water Consumption
Seal water consumption dropped from 1000 GPM to <200 GPM.