Industrial Maintenance Roundtable NSW

Common Interest Workgroup (CIWG)

Report from Meeting on May 9th 2007 at
ANSTO

Best Practice in
Process Pump
Maintenance &
Reliability

This document is compiled from discussions during the NSW IMRt

Common Interest Workgroup (CIWG) on Best Practice in Process Pump
Maintenance & Reliability. Document Compiled by Peter Todd - NSW IMRt
Facilitator
 Best Practice in Process Pump
Maintenance & Reliability
Attendance List
Name Organisation
Matt Richards ANSTO
Barry Siddons ANSTO
Craig Torzillo ANSTO
Darren Elliott Bluescope Steel
Daren Templeman CPCM BSL
Col Matheson CPCM BSL
Graeme Cox Caltex
Terry Edwards Caltex
Behdad Choheili Delta Electricity Western
Wayne Vought Delta Electricity Western
Eddy Valentinis Hunter Water
Greg Moore Hunter Water
Frank Dyrssen Northparkes Mines
Hank Cornelissen Northparkes Mines
Hugh Maccallum OneSteel
Alison Pepper Rio Tinto Coal Aust
Tony Hutchinson Rio Tinto Coal Aust
Perry Johns Shell
Peter Todd SIRF Roundtables
Bruce Maunder Sydney Water
Mikaila Derome Sydney Water

Introduction
The NSW Industrial Maintenance Roundtable (IMRt) held a Common Interest Work
Group (CIWG) meeting on Best Practice in Process Pump Maintenance & Reliability.
This meeting was on the 9th May 2007 and was hosted by Matt Richards from ANSTO
Lucas Heights. Matt gave a short presentation on ANSTO’s new OPAL nuclear reactor to
start off the meeting. The meeting was attended by 21 people from 12 organisations.
Process pumps are classified as centrifugal pumps for relatively clean fluids (not slurry).
Centrifugal pumps are one of the most widely used equipment items in industry and there
can be significant cost savings and improvements in operational reliability if good
practices can be successfully implemented and sustained. The NSW IMRt is also holding
other CIWG meetings in 2007 on Equipment Best Practice including motors and
gearboxes.
The IMRt is a maintenance networking organisation coordinated by SIRF Roundtables
(SIRF Rt) www.sirfrt.com.au . This report gives feedback to meeting attendees and other
interested parties. The meet included the development of a comparison matrix, which is
shown on the following pages. This matrix was filled out by attendee organisations to
enable comparisons to be made between organisations on the issues discussed.

2
 Process Pump Best Hunter Water Delta Electricity Western Rio Tinto Coal Aust Bluescope Steel CPCM Shell
What types of Submersibles - 5 to 6 yrs Double casing, Horizontally Slurry - 9 months (DM) Wernett 100 315 Centrifugal
pumps do you have Grit pumps - 2 to 3 yrs split, Inner Volute type Water 5 yrs + Munch Multi Stage
& what are their Sludge - Post Disp Submersible - 2 yrs Life 2 yrs Max Vertical Turbine
typical service Centrifugal water - 6 to 8 yrs (Acid Application)
lives?
What types of seals Mech seals - Pullman or Pump Mechanical Seals - John Crane Mechanical Seal Viton 1 to 2 yrs Flowserve - 85%
do you have & what OEM std supply & Flowserve Glands Others - 15%
are their typical Some glands on older pumps Life 2 to 3 yrs approximately Life > 100 months
service lives? Split mech seal - retrofit

What are your main Sewer- Choking(inlet blocked) Mech Seal - Cooling Water Blockages - Oversize material Flow Rates Seals
pump reliability Seal failure - Many reasons starvation Wear - Liners & Impellors Seal Failures - Acid
problems? Flygt N Series - Low life Pump efficiency Ingress

What is the main Runtime comparisons Performance based Performance for DM (pressure CM (Called CDT) Both CM & PM
maintenance between pumps at location CM recommendations trend V motor amps) CDT operator checks
strategy (CM or (runtime relative to flow rate) Condition Mon VA for brgs pumps every 14 days
PM)? What trigger Submersible OTF Visual, Performance Based
overhauls? Performance (bog down)

What are the main SCADA - Some pressure Vibration monitoring Process observations Vibration Analysis Vib Analysis
pump monitoring Water in seal barrier oil & Oil analysis Visual Citech - Computer screens Performance
methods used? motor temp for submersibles Performance testing Visual - From Prod & Maint monitoring
Motor out of current limit alarm

What approach is Alternate duty by PLC each Routine changeover from Duty No Stand-bys Line must stop Standby run for 1 hr
used for regular start. to Stand-by 1/2 to 1 hrs for fitter to every 2 weeks
changeover to change over pumps
stand-by pumps?
How is pump Submersible - Sealed Internal auxiliary oil pump Own lubies. Routine PM. Add Permalube greasing Lube contractor
lubrication Others - Manual on PM & supplying lube oil to the pump listed CC's system PM crew
managed? some Auto Lubes bearings VA also triggers additional + manual greasing every 6
greasing weeks

Process Pump Best ANSTO Caltex (NSW) Sydney Water Northparkes Mines OneSteel
Practice
What types of Centrifugal United Pump Kobe (rotorjet) Submersible - 5 yrs Geho Diaphragm Pumps Centrifugal Water - 2 to 8 yrs
pumps do you have Submersible TKL (Flowserve) Goulds Centrifugal water - 10 yrs x2 Positive Displacement for
& what are their Mono Ingersol Rand Sludge pumps - 2 yrs /Grit Flyght Pumps - hydraulic & lube oil - 5 yrs
typical service Diaphragm Gorman Rupp - Life 4 yrs Dosing Pumps - 2 yrs Submersible
lives? Seals 3 to 5 years Warman Centrifugal
What types of sealsSeal - OL John Crane Mech Cartridge Split Gland Packing Gland packing?
do you have & what Viton Pusher & cartridge Any Brand Mechanical
are their typical Mechanical Flowserve (BW) Gland
service lives? Gland Service Life 4 yrs Life 2 Yrs
Flowserve
What are your main Seal Failure Seals Sewer Chokes Reliability Bearing Failure
pump reliability Bearings Pumps run dry Seal Failures Fit for purpose - Water in Lube
problems? Seizure applications - Lack of Lube
- Poor Installation
What is the main Corrective Performance Based Preventive on larger Equip Daily PM's / Visual Run to Failure
maintenance Maintenance RTF, Reactive on smaller Yearly Dismantle Moving toward CM
strategy (CM or 10% Preventive Inspections
PM)? What trigger Maintenance Oil Sampling being
overhauls? implemented

What are the main Eyes & Ears Hand held vibration monitoring CM - Vibration On-line for GEHO Bearing temps continually
pump monitoring Temp Rockwell (IRD) Inspection Audits Visual for rest monitored and alarmed on HI
methods used? Vibration Performance Trending pressure & Amps
Ad Hoc vibration & oil Analysis
Just starting to monitor pump
Performance (flow pressure)

What approach is Rotate Monthly Run Standby pumps once a Regular Duty Change As Needed No clear policy
used for regular Auto changeover week for 2 hours Operators generally operate
changeover to Standby standby pumps once a month
stand-by pumps?
How is pump SAP Dedicated lubrication man with Monthly Lube schedules Daily PM's Some pumps have oil systems
lubrication When Required after hours - plant operators Same auto-greasers Self Lubricated for Some greased - unsure of lube
managed? Oil bath - Auto No common approach GEHO strategy

3
Issues for Discussion
The below list of items were identified for discussion in the Meeting.
• What type of pump reliability problems you have?
• Bearing problems with pumps
• Pump suction problems
• Overhaul procedures, standards and QA systems
• What spares strategy you have for you pumps
• What Condition & Performance Monitoring you use
• Installation procedures, standards and QA systems
• Lubrication issues and strategies
• Gland seal alternatives, performance and improvement strategies
• Selection and upgrading of pump materials
• Management of stand-by pumps
• Experience with in-house vs outsourcing for repair/overhaul of pumps
• Design, Specification and Procurement standards for pumps
• Training on maintenance and operation of pumps
• What KPI’s do you use to help manage pumps (eg. MTBF)

Process Pump Best Practice

Meeting Attendees
The meeting attendees were from a wide range of roles within their organisations but all
actively involved and interested in pumps. There were tradesmen, maintenance planners,
workshop supervisors, contract administrators, condition monitoring engineers, reliability
engineers, technical support engineers and maintenance managers.

Pump Seals
Retrofitting Mechanical Seals
The first question came from Hunter Water and was about the viability of converting
packing gland pumps to mechanical seals. The Shell attendee indicated that they use API
standards that specify mechanical seals for non-water applications and had converted
many pumps due to environmental and safely issues from leakage. These conversions
were successful except where the casing was not adequate to take the stuffing box
machining modifications. Sydney Water commented that there can be problems where the
distance between the inboard bearing and the impellor is large with a slender shaft. A
gland seal provides shaft support but a mechanical seal does not and excessive shaft
deflection will cause mechanical seal problems.

The API Standards (American Petroleum Institute) that Caltex and Shell use as guidelines
for best practice are available off the internet. The standards that Caltex most commonly
use are as listed below but it should be noted that they do not substitute for Manufacturers
recommendations and standards.
• API 610 - Recommended Practice - Centrifugal Pumps for Petroleum,
Petrochemical & Natural Gas Industries.
• API 674 - Recommended Practice - Positive Displacement Pumps - Reciprocating.
• API 682 - Recommended Practice - Pumps - Shaft Sealing Systems for
Centrifugal and Rotary Pumps.
• API 686 - Recommended Practice - Machinery Installation & Installation Design.

4
There was agreement that there is efficiency, reliability and life cycle cost gains between
packing glands and mechanical seals if reliable operation is achieved. Also because gland
packing requires a continual minor leakage in operation, they can cause environmental
issues such as corrosion with water and worse with more dangerous fluids. ANSTO gave
the experience for there old Reactor the pump life was increased from 18 months to 3 to 5
years with the conversion from gland packing to mechanical seals. Sydney Water
specifies only mechanical seals for its pumps and achieved from 3 to 5 years seal life in
sewage applications and up to 10 years life in water applications. It was suggested that
gland packing is still the standard for emergency and fire pumps as they are less likely to
fail completely when they are required in an emergency.

Mechanical Installation Issues

Some examples were given where pump mechanical seals did not achieve reasonable life
(at least 2 to 3 years). Site installation issues were given as the cause of some previous
short seal life with some Delta Electricity Feed Pumps with high fluid temperature. As the
seals had to be set up on-site some very minor installation variations by tradesmen (with
the best of intensions) was enough to cause very short life. Shaft end float relative to the
seal was found to be most critical as a small variation could easily overload or underload
the seal. Also mechanical seals can be easily knocked and damaged during installation. In
the Delta Electricity example they had the seal supplier add extra setup tabs in the seal to
make the seal less flimsy for installation. The suggestion from the Delta attendee was for
applications that require site installation of shaft/seal assemblies, to use Cartridge type
seals as the installation is much quicker and there is much less risk of installation
problems. Poor alignment of seal to hosing was suggested as a key cause of poor seal life.

Seal Cooling/Flushing/Barrier Fluids

An example of the criticality of seal cooling water was given by Delta Electricity. A
group of feed pumps had a common seal cooling water supply and unknown to Delta the
details of the installation had produced uneven flow to the different seals. The seals with
inadequate flow had significantly less seal life. It was suggested that where seal
temperature is an issue, seal cooling fluid flows and temperatures should be initially
measured on commissioning and checked regularly. A example diagram of a cooling
water system for a double mechanical seal is given below.

Double Mechanical Pump Seal with Cooling/Flushing Piping

www.tappsa.co.za/archive/Journal_papers/Water_conservation/water_conservation.html

5
A Bluescope Steel attendee who had previously worked in a paper mill told of an
example of poor mechanical seal life that was traced to operator start-up procedures. The
particular pumps had a separate isolation valve for the seal water supply and it was easy
for an operator the start up one of the pumps but forget to turn the seal water on.
Installing automated isolation valves that opened when the pump was started solved this
seal life problem.

Rio Tinto Coal Australia attendee gave an example of a slurry pump that had occasional
supply blockages. The increased suction pressure during the blockage caused the seal to
open and let contamination enter the faces causing fast seal failure.

Cleanliness of cooling, flushing or barrier fluids that come in contact with the mechanical
seal is important for seal life. Adequate throat bushing between the seal and the pump can
be important to reduce contaminant entry into seals.

Mechanical Seal Condition Monitoring

The submersible pumps used by Sydney and Hunter Water have on-line monitoring of the
seal condition. These pumps have an oil barrier fluid between a double mechanical seal.
If water gets past the primary seal and mixes with the oil them a moisture sensor alarm is
activated. Sydney Water attendee suggested there are now models available that can trend
the moisture level in the oil, which avoids false alarms due to very slow moisture ingress
over time. The Figure below shows an example of the seal arrangement with the oil
chamber in yellow. This type of monitoring would be applicable for other pumping
applications where being able to predict seal failure would minimise operational or
environmental risk.

Cross Section of a Submersible Pump Mechanica Seal

http://www.lawrencepumps.com/products/Submersible-subpages/subm_seal_7_lines_defense.html

6
Seal Suppliers and Technical Support
The advice from Delta Electricity was that if you have experience of short mechanical
seal life, don’t be too quick to blame the seal itself. Installation and operational issues are
the most probable cause. Seal suppliers are the best source of technical advice and you
should demand a comprehensive post-mortem inspection report for all seals that fail or
are removed from service.

The Shell refinery uses 85% Flowserve mechanical seals and has a fixed price contract
with them to support repair/overhaul of seals and to assist with problem solving and
reliability improvement. Flowserve supply a comprehensive inspection report for all seals
removed from service. Shell tends to have a contractual arrangement with Flowserve
worldwide and is reviewed regularly. Caltex refinery has a similar arrangement with John
Crane Mechanical Seals and they have a representative that works from Caltex’s main
workshop.

The comment was made that Flowserve’s mechanical seals division and pump division
are separate organisations and don’t talk to each other. Positive comments about both
organisation were provided by attendees.

Delta Electricity Western are currently using a less well known mechanical seal
repairer/supplier call Stevco (http://www.stevco.com.au/ ) based in Narellan NSW
(Stevco Seals & Pumps 11 Samantha Place, Smeaton Grange NSW 2567 - also in Vic &
SA). They provided seal overhauls 60% cheaper then the OEM for Delta and can provide
good technical support.

The Shell attendee stressed that when fluid other than water are used it is important to
confirm compatibility between the fluid and O ring and seal materials used. An example
was given of where a very low level of chemical additives in a petroleum fluid was
enough the cause fast failure of seal O rings.

It was suggested the using a Root Cause Analysis process to solve seal problems is the
best approach. As there can be operational process, pump design, installation, storage,
transportation and seal design issues involved, an appropriate group of people need to be
brought together to solve seal problem. The starting point is usually having a seal
repairer/supplier that can produce good quality inspection reports of removed seal. It was
suggested that organisations should build a relationship with recognised seal expert and
the option of larger organisations to form alliance relationships with seal
suppliers/repairers.

Pump Performance Problem

The OneSteel attendee came to the meeting with a specific pump performance problem
that he presented to the group. The application was on a recirculating cooling water
system where two dry mounted pumps are pumping out of a sump through separate
suction pipes. One pump operates successfully while the other pump does not generate
enough flow to run the system effectively. This situation has existed for a few years and
the previous investigations have not verified a cause. There was much discussion during
breaks of the details and the attendee now has a plan to do further investigations.

Design, Installation and Commissioning Problems

The observation was made that design and project groups who deliver new pumping
systems are not typically interested in detailed reliability and maintainability issues, as

7
they typically have their performance measured by the cost and commissioning deadlines.
Operations and maintenance people have to be integrally involved with projects early and
encourage a Whole of Life Costing approach to management, design and installation
project personnel.

Often when there are commission and warrantee problems occur with new equipment,
supplier and other involved are more interested in protecting there financial risks than
solving the problem. This slows down the problem solving process as there is rarely risk
for supplier from going slow and there is often only greater risk in sharing any
information found. In this situations warrantees can cost a lot more than they are worth,
compared with no blame situations where problems are resolved quickly.

Pump Condition Monitoring Methods

Hunter Water currently uses no advanced vibration monitoring of its pumps but relies on
its installed redundancy. Hunter Water uses their SCADA system to monitor the
performance of their pumps. Most of their pumping application reacts to a low and high
level alarm to switch pumps on and off. The time it takes the pump to go from low to
high level (eg fill a tank) give a good indication of its flow rate. Each application has two
pumps which work alternately and the time taken by each pump gives a quick indication
of their relative performance/condition. Sydney Water uses the same approach. Their
greatest number of pumps is submersibles, mostly on sewer applications. As discussed in
the seals section the standard design of submersible pumps used have on-line monitoring
of seal leakage and motor temperature. Their SCADA system can also monitors line
pressure and other variables such as number of starts and run time.

Delta Electricity Western use extensive Condition Monitoring. Vibration monitoring is

carried out manually monthly by a CM contractor based locally (CCI Pope). The scope is
“if it turns it gets vibration monitored”. Large critical machines such as the feed pumps
also have on-line vibration measurement. They have a Performance Analysis group that
do a wide range of performance tests including Head & Flow efficiency testing of pumps.
There is also extensive water and oil analysis carried out. Delta relies heavily on
condition monitoring and has had good experience in predicting failure. Overhauls are not
done on time basis but only on condition. One interesting technique that has been used on
critical pipework is an ultrasonic monitoring of pipe wall thickness that does not require
the lagging to be removed.

Shell uses a 5 week cycle for its manual vibration monitoring system for its main process
equipment. This system predicts most vibration related problems with few misses. They
have been using RCM processes to upgrade routine PM/Inspection systems. Shell has
some strong corporate standards and they have a rule that PM’s can only be deferred once.
They have extensive process monitoring with 80% of pumping systems having both
suction and discharge pressured monitored. Many other parameters such as fluid flow and
density are monitored. There is some monitoring of pump mechanical seal barrier fluid
pressure for monitoring seal condition. Shell use ultrasonic monitoring of pipework wear
rates and suggested to use two or three measurements of a location to be able to predict
future likely failure.

The Caltex Vibration Monitoring Group - IMI (Integrated Machinery Inspection) is a

Chevron based philosophy that goes back to before 1980. They use the Rockwell data
collectors and software for routine VA and on-line vibration systems from Bently
Nevarda for there large machines. They have around 700 pumps and includes 250

8
standby “spares” that are generally turbine driven. The CM group issues a Vibration
Summary Report via a Lotus Notes database, to all interested people advising of what
repairs are required. A blank Summary Report is included as an attachment. This report
shows their three levels of defect response.
• Phase I - Early stage of failure, no immediate concern.
• Phase II - Predictable failure stage, schedule replacement within 3 weeks.
• Phase III - Failure imminent, should not be operated.

OneSteel Rod Mills use Vibration Condition monitoring but currently on a somewhat
rather adhoc basis as currently some maintenance planners are not full believers in the
technology. There is still both CM and time based PM activities occurring.

Northparkes mine use vibration monitoring on its pumps. Their pumps are also checked
by fitters doing daily inspections.

Bluescope Steel Sinter Plants main application is for cooling pumps and most pumps
have a backup standby unit. They have about 15 to 20 units in service. Routine vibration
monitoring is carried out monthly with only operating units measured. There are about
10% of bearing/ mechanical faults that are missed. RCA failure analysis is carried out on
repeat failures. There is no regular routine of changeover between standby and operating
pumps. Operators inspect pumps every shift and generate a third of the maintenance
triggers.

The Rio Tinto Coal Hunter Valley Coal Preparation Plants use SKF to do a 28 day
vibration monitoring route for critical pumps but an 84 day routine for pumps with
redundancy. Almost all pump bearing problems are predicted by this monitoring.
Currently this is not carried out on all pumps and they have a larger percentage of their
pumps that are not on vibration monitored. Hunter Valley has reliability engineers to do
RCA on failures by striping down and inspecting faults to determine PF Intervals. The
coal prep plants have central process control systems that can monitor pump heads, flows
and other parameters that can monitor pump efficiency. As the materials being pumped
are mostly slurries, wear is a significant problem. A lot of equipment is changed out on a
time basis rather than on a condition basis. Ultrasonic monitoring of pump casing
thickness has been successfully carried out to monitor wear of the casings. Life of pumps
in slurry applications is about 2 years and for clean applications about 6 years.

Bluescope Steel Springhill CPCM section’s most critical pumps are for their acid
circulation systems. The Springhill works have had a long history of successfully using
vibration monitoring and have a CDT (CM) inspection that monitors their rotating
equipment regularly. The high criticality acid pumps are inaccessible during operation for
safety reasons and so have permanent accelerometers installed that the routine vibration
monitoring instruments connect into. There is standby pumps for these application but
they can’t be changed over on-line so the pumps are occasionally run to failure rather
than shutting the process down early.

ANSTO have historically not used Vibration Condition Monitoring for their reactor
pumps but carried out maintenance on a Calender Time basis and relying on process
parameter monitoring and redundancy to maintain service reliability. Process parameters
monitored include flow, pressure, motor amps and temperature. Currently pumps are only
overhauling as required.

9
Sydney Water carries out vibration monitoring of its above ground pumps monthly. As
previously discussed they use various process parameters to monitor the submerged sewer
pumps including pressure and low to high level pump operating time to indicate flow
efficiency. Choking (blockages) are the most common problem for sewer pumps. Pumps
are continuously changed over automatically between operational and standby on each
operational cycle.

A question was asked about dead head flow tests for monitoring pump internal wear but
none of the attendees was using this technique routinely.

Pump Lubrication
Oil Lubricated Pumps
The Caltex and Shell refinery pumps are mostly oil lubricated with Constant Level Oiler
systems installed on each pump. These are a small glass bowel external unit that
automatically tops up the pump bearing casing oil levels and can easily be inspected for
any top-ups required. Caltex has a dedicated lube tech person. They use ALS for oil
sample bottles and Laboratory Lube Analysis.

At Shell, maintenance carries out lubrication work. They have recently been doing RCM
analysis and have decided for small oil compartments such as in pumps the oil is changed
yearly but for lager compartments the oil is tested with a laboratory analysis and only
changed as required.

The Delta Electricity Feed Pumps bearing are oil lubricated with a oil system volume of
1,400 litres. Oil is changed only with deterioration of oil condition with regular Rbot tests
carried out to determine the state of oil oxidisation. They have found when the oil
oxidises to a level where action is required, only changing out 20 percent of oil is enough
for the oxidisation parameters to recover with the new oil and its additives. The feed
pumps have had problems with water entering the lube system through the coolers.
Modifications have been made to ensure the oil cooler water supplies are at a lower
pressure than the oil so that oil leaks out rather than water getting into the oil.

Grease Lubricated Pumps

ANSTO raised a problem that they had with their technicians over greasing pump
bearings with grease guns, which has caused problems. Fitters now do all the greasing.
Delta Electricity indicated that they open up greased bearing to remove old grease. There
was a discussion around the use grease relief ports on larger electric motors.

A number of the attendees used Auto Lubes, Memo Lubes or other brands of individual
bearing automatic lubrication system. There were discussions on the merits and problems
of these single point automatic lubrication systems.

There were discussions around the use of Ultrasonic Vibration monitoring instruments for
monitoring lubrication. The Shell representatives indicated that these Ultrasonic
instruments were effective for monitoring if lubrication was effective, minimise the
amount of grease required for lubrication and can help to optimise the required frequency
of lubrication.

10
Alignment
There was general agreement that Laser Alignment should be used for pump installations
to achieve high reliability for pump and motor bearings. OneSteel have a policy for use of
laser alignment for couplings. Good training for those who use these systems was
considered vital and it was considered that the availability of an expert to assist on
difficult application and generally coach users is very useful. There was also general
agreement that all installations that require alignment should be set up with jacking screw
for making adjustments.

Caltex, because of its processes required Intrinsically Safe laser alignment equipment.
The alignment shim packs that Caltex use and found to be the cheapest are from
Maintenance Systems in Victoria, web address www.maintsys.com.au . There was
general agreement that making your own shims is generally not a worthwhile proposition
as purchased shim packs give a much better alignment result.

There were discussions on the advantages of being able to do alignment on machines with
couplings fully connected, which is the standard approach for laser alignment. This
makes hot alignment check possible as machines can be heated up to full temperature and
quickly shut down, isolated and the alignment check made without significant loss of
temperature. The other method of checking hot alignment offsets is setting up various
temperature measurement points on pump and motors casing and to calculate thermal
expansions from these casing temperatures.

Pump Overhauls
Caltex overhaul 90% of their pumps in-house in their own workshop and they have their
own balancing machine and are happy with the results they get. As mentioned previously
they have John Crane seal representative based in their workshop to manage the quality
of seal installations. Shell also maintains a central workshop and a number of rotating
equipment specialist tradesmen to overhaul pumps and some overhauls are carried out
externally by OEM’s etc.

Sydney Water used to do all the overhaul work on their pumps but now a large
percentage of the overhauls are outsourced. They tend to use local overhaul service
providers so that it is easy visit the supplier to keep check on quality control issues. There
were discussions around the need to ensure quality control of any overhaul or repair
activity to ensure reliability. Bluescope Steel attendee indicated that to achieve the quality
of repair/overhaul service on pumps he regularly visits the repair workshop. His
experience was that when this was not done the quality and detail of the repair was not
maintained resulting in reliability problems.

A number of attendee organisations such as Bluescope Steel and Hunter Water used
external Service Providers to carry out pump overhaul work.

Pump Training
Hunter Water use and would recommend an organisation called KASA who do their
pump training (PO Box 464 Kingswood, NSW 2747. 02 47537649, www.kasa.com.au).
Hunter Water has KAS doing in-house Pump Fundamentals training on 19/7/07 in
Newcastle (some paying external guests may be an option). If you want a look at
the KASA pump training manuals Hunter Water Head Office has copies (Ring Greg on
(02) 4979-9732).

11
Rio Tinto Coal Australia use and would recommend an organisation called Strategic
Achievement to do their pump training (Strategic Achievement PO Box 429,
Scarborough, WA 6922 Ph: +61 8 6210 1852 www.strategicachievement.com.au). A
Hunter Water attendee also recommended this course.

Both these organisation run Pump Training Courses at various location around Australia.

12
Appendix

• Caltex Condition Monitoring Summary Report Format

• Flowserve Removed Seal Report
• Seal Piping Information Poster

13
 Machinery Vibration Summary Report
To Area Superintendent (print name)

Area Operations Specialist (print name)

Maintenance Coordinator (print name)

Maintenance Planner (print name)

Electrical Coordinator (print name)

Machine Shop Supervisor (print name)

IMI Analyst (print name)

From Technician (print name) Date Issued: / /

Notification Number Date Issued: / /

Recommendations
Equipment No. Analysis Report Note Phase Code

Failure Code
If vibration reading reaches the ALERT LEVEL, carry out further investigation
immediately. Contact IMI Analyst for advice if results need clarification.

Note: (1) Anti-Friction Bearing

Note: (2) Other Components Condition
Phase I Early stage of failure, no immediate concern.
Phase II Predictable failure stage, schedule replacement within 3 weeks.
Phase III Failure imminent, should not be operated.
Code (a) Monthly Survey Except for any equipment listed, at the time of survey all recorded
vibration levels were acceptable.
Code (b) Special Survey The above equipment was surveyed on request. Except for any
required repairs listed, at the time of survey all other recorded
vibrations were acceptable.
Code (c) Post Repair Survey This equipment was surveyed after recent repairs. Except for any
required repairs listed, at the time of survey all other recorded
vibrations were acceptable.

Recommended
by (print name)
(signature)

Date / /

14


   

 







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 P5518B Carbon Stationary Face
September 2006 Failure on work order 6000015705

P5518B Silicon Carbide Rotating Face

September 2006 Failure on work order 6000015705

P5518B Viton Stationary Face Gasket

September 2006 Failure on work order 6000015705