Challenge

The client desired to increase pump mean time between failures (MTBF) and improve profit margins by addressing root causes of equipment issues through a focused defect elimination process. This was supported by strengthening quality assurance and quality control (QA/QC) practices, updating operator rounds to enhance early issue detection, and implementing a more effective lubrication program. Together, these initiatives were aimed at boosting pump reliability, reducing maintenance costs, and enhancing overall operational availability.

Solution

Pump failure causes were reviewed in detail by Valdes Architecture & Engineering staff, and a pump MTBF improvement plan was developed. The plan included defect elimination, stronger QA/QC work processes, updated roles and responsibilities for the workshop and field supervisors, updated monitoring rounds for the operators and field technicians, and an updated lubrication program that included improved housekeeping and storage of the lubricants, and updated lubrication rounds.

Impact

The pump reliability program helped this site deliver the following improvements within four years: pump MTBF went from 44 to 112. Out of service pumps reduced from 149 to 27, or 1.7% of total pump population (1,624) compared to industry minimum recommended of <2%. Unhealthy pumps were reduced from 120 down to 46. Pumps being reworked reduced from 36 down to five per year. Robust processes and procedures were implemented to keep gains sustainable. All the above resulted in over $5 million dollars of cost reductions from fewer repairs, and 15% of availability related margin improvements.

Services

Maintenance, Reliability & Asset Integrity