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.

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.