Laser shaft alignment improves pump reliability

A particular case of interest is that of a large acetate chemical plant in Derbyshire, UK. Substantial improvements in plant operation were achieved after the introduction of a comprehensive pump alignment and condition monitoring programme.

The production process requires materials to move mechanically around the plant from one stage of the process to another. Some 260 pumps are used in this plant, so it is vital that the plant is reliable and available both when idle and active. Maintenance was more or less a fire-fighting exercise until 1996.

The plant engineer at the time convinced management of the need to take a more proactive approach to maintenance performance and pump performance monitoring. Using the laser shaft alignment system and condition monitoring equipment, a coordinated plan was implemented to improve plant performance.

By applying a combination of laser shaft alignment, with newly refurbished machines and machine alignment installed where possible, plus routine monitoring of plant conditions, coupled with a thorough overhaul of installed components such as mechanical seals, bearings and seals, the plant began to see significant savings in the maintenance of all pump systems.

The programme, now well established, has returned substantial dividends. Plant reliability has improved to over 46 months Mean Time Between Failure (MTBF) and routine pump repairs have been drastically reduced.

A comprehensive action plan was implemented by engineers to achieve these extraordinary savings at the plant, including key factors such as:

• Commitment of engineers and management to the programme
• Patience!
• Laser alignment
• Monitoring of conditions
• Training
• Root cause analysis.
• Careful selection of mechanical seals.
• Careful selection of bearings.
• Partnership with suppliers.
• Improved design and installation of pipelines.
• Careful selection of pumps.
• A selection  of advanced lubrication systems.

If you are interested in learning a little more about how to improve pump reliability with laser shaft alignment, we invite you to learn about how industrial maintenance can be a profit centreas well as to subscribe to our newsletter.