The size and type of pumps used for different purposes in the water industry varies enormously; as does the costs of failure. Managing such a large stock of variable pump types is extremely complex and demanding. To be effectively managed, pumps need to be grouped and allocated their own programme, according to factors such as:
- Consequential risks of failure.
- Management effort scaled by whole life cost.
- The pump duty; steady intermittent and variable.
- Maintenance/replacement schedules.
This project will deliver cost-effective manageable plans for each pump group based on operational stress envelopes, using operating data such as: hours run; start/stop frequency; and pumped material. The management programme will also incorporate key pump management factors such as whole life costs (WLC) - including carbon, proactive and reactive maintenance, monitoring, stress factors in service and service failure costs.
- Potentially significant savings.
- Mechanism to include carbon considerations in pump management.
- Clearly defined management methods for different pump groups.
Bringing in specialist expertise from the Pump Centre, this project will:
- Review and build on recent relevant pump management work, including UKWIR projects on data collection (WIDER) and deterioration models.
- Set the categories of pumps by: type; duty; size; maintenance and operating regime; and failure data. This will include stress factors e.g. start/stop rates, run time and severe duty.
- Define pump groups, and for each pump group create the WLC (including consequences of failure).
- Identify pump management elements and assign costs to them, including, scheduled/unscheduled maintenance, refurbishment, and pump monitoring methods.
- Build WLC models, with a carbon price element, for each of the pump groups and calibrate with client data.
- Develop a stress envelope, linking run time, start/stop rate and operating regime to the timescale to replace the asset.
- Develop a matrix of management operations against pump groups showing WLC benefits.
- Produce, in consultation with participants, a pump management implementation plan.
- Interim report on the pump groups and estimated WLC.
- Consolidated report on pump management by groups, and the research. into the costs of maintenance, monitoring and refurbishment.
- Implementation plan.
- Dissemination seminar.