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<p>The switchover between duty and standby pumps is critical for ensuring operational flexibility and system reliability across various industrial processes. Conventional approaches often prioritize minimizing start-stop cycles without fully accounting for economic factors, failure rates, or system-specific conditions. To address these gaps, this study introduces an analytical framework aimed at optimizing the duty-standby pump switchover frequency by integrating reliability and economic considerations. The framework incorporates cost estimation using Monte Carlo simulation with a triangular distribution, which requires minimal input parameters: minimum, most likely, and maximum values derived from historical data. By integrating failure rates, switchover costs, and the consequences of multiple failures, a cost function is constructed. Convex optimization of this function ensures a global minimum, identifying the optimal switchover interval. This approach allows industries to enhance pump system reliability while improving overall cost performance. The pump operation schedule is dynamically updated when the recalculated switchover interval deviates from the initial interval by more than a system specific threshold. Initial implementation has demonstrated success, with duty pump failure rates reduced by 8.3% for vacuum pumps and 11.6% for slurry pumps. Furthermore, the framework is adaptable to more complex configuration, including multiple standby pumps and &#xa0;<i>k-out-of-n</i> systems, offering a comprehensive solution. The optimized pump schedules have been developed to demonstrate the practical application of the methodology in enhancing operational reliability. The findings underscore the efficacy of this approach in delivering improved operational efficiency, cost-effectiveness, and competitiveness in industrial settings.</p>

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Optimizing pump switchover frequency: integrating the failure rate and economic considerations in the process industry

  • 期刊论文

  • 发表日期：

    2025年6月1日

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  • Mohammad Aiqur Rahman

摘要

The switchover between duty and standby pumps is critical for ensuring operational flexibility and system reliability across various industrial processes. Conventional approaches often prioritize minimizing start-stop cycles without fully accounting for economic factors, failure rates, or system-specific conditions. To address these gaps, this study introduces an analytical framework aimed at optimizing the duty-standby pump switchover frequency by integrating reliability and economic considerations. The framework incorporates cost estimation using Monte Carlo simulation with a triangular distribution, which requires minimal input parameters: minimum, most likely, and maximum values derived from historical data. By integrating failure rates, switchover costs, and the consequences of multiple failures, a cost function is constructed. Convex optimization of this function ensures a global minimum, identifying the optimal switchover interval. This approach allows industries to enhance pump system reliability while improving overall cost performance. The pump operation schedule is dynamically updated when the recalculated switchover interval deviates from the initial interval by more than a system specific threshold. Initial implementation has demonstrated success, with duty pump failure rates reduced by 8.3% for vacuum pumps and 11.6% for slurry pumps. Furthermore, the framework is adaptable to more complex configuration, including multiple standby pumps and  k-out-of-n systems, offering a comprehensive solution. The optimized pump schedules have been developed to demonstrate the practical application of the methodology in enhancing operational reliability. The findings underscore the efficacy of this approach in delivering improved operational efficiency, cost-effectiveness, and competitiveness in industrial settings.