Contributing Re.engineer: Keith Lapeyrouse, Process Reliability Solutions, www.prs-llc.com
Challenge: It’s amazing how pesky condensate pumps can be. But think about it. They are the least important part of a project typically bought at the lowest cost by the least experienced member of the team. Forty years ago, I was working at a chemical plant and it had 3 low pressure (L.P.) condensate return systems that was costing the plant $22K per year in maintenance.
Brackground: Let me describe the three different systems:
Results: One day, when the 2nd system pump failed, I used the spare from the 3rd system and it became my second system. It ran great! I started staving the $7k/yr. After it ran well for a while, I convinced the plant to upgrade the 1st system. The new system installed was the cost of maintenance for a year. So what's the point of the story? The cash was my salary at the time. The NPV is about $250K at this point. Fixing the small things pays big dividends!