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Applications

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Diaphragm Life

Diaphragm Life

Problem: A major international chemical company in New Jersey uses 3” air operated double diaphragm (AODD) pumps with PTFE diaphragms to pump a highly aggressive chemical through candle filters from an overhead tank. Part of the filtered chemical is recirculated at 30 psi back to the pump’s inlet. Rapid diaphragm failure was occurring in the AODD pumps. These pumps are generally limited to a maximum inlet pressure of 10 psi when equipped with PTFE diaphragms. As a result of the excessive inlet pressure, the PTFE diaphragms in these pumps lasted only a few hours.

Power Plant

Power Plant

Problem: A 300 megawatt power plant required a chemical feed system to supply hydrazine to a boiler. The hydrazine acts as an oxygen scavenger, and must be delivered in a precise and consistent quantity. While metering pumps can deliver chemicals in precise amounts, their reciprocating action will not allow delivery in a smooth and consistent flow.

Label Adhesive Application

Label Adhesive Application

Problem: A manufacturing facility needed to apply glue precisely to labels on plastic containers, but they were experiencing significant quality control issues. Their existing AODD pump produced inconsistent and highly variable flow due to hydraulic pulsations inherent in the pump design. These flow fluctuations made it impossible to apply the adhesive evenly and accurately to the product labels, resulting in defective products, waste, and potential production slowdowns. The challenge was particularly difficult given the nature of the material—a water-based adhesive with high viscosity (110,000 centipoise)—which amplified the pulsation problems.

Chemical Process Leak in Boston

Chemical Process Leak in Boston

Problem: A chemical processing plant in the Boston area experienced a critical failure when the diaphragm on their AODD pump tore during operation. As a result, process fluid began escaping through the muffler, creating both a safety hazard and potential contamination issue.

Additionally, the system was experiencing vibration, causing the connected pipes to shake. This combination of fluid leakage and excessive vibration posed risks to personnel safety, equipment integrity, and process reliability, requiring immediate attention to prevent further damage and potential downtime.

Chronic Pulsation Issues at Power Plant in Central PA

Chronic Pulsation Issues at Power Plant in Central PA

Problem: The facility experienced persistent pulsation and vibration in a process line operating with two pumps. Operators noted:

- Poor pulsation control
- Unstable pressure readings
- Concerns that the dampener was “not working”
- Consideration of taking the dampener offline


Initial discussions suggested potential equipment malfunction. However, system layout and installation practices had not yet been fully evaluated.

During the site visit, the system configuration was reviewed in detail. Two critical issues were identified:

1. One Dampener Serving Two Pumps
Both pumps were discharging into a single pulsation dampener—an arrangement not suitable for proper attenuation or balanced operation.

2. Improper Dampener Placement
The dampener was installed well outside the recommended 10 pipe diameters from the pump discharge. At this distance, the unit could not effectively mitigate pressure fluctuations.

These conditions explained the apparent performance issues despite the dampener itself being fully functional.

Waste Liquids

Waste Liquids

Problem: A large manufacturing plant located in Japan uses air operated high pressure injection pumps throughout their plant to pump out waste liquids from reactor vessels. The reciprocating action of the pumps creates a pulsating flow which vibrates the plumbing, producing loud noise resulting in worker complaints and possible safety issues.

APPLICATIONS
View All Bottling Line Power Plant Chicken Plant Deionized Water Dosing in R&D Lab Oil & Gas Drilling Hazardous Waste Chemical Process Leak in Boston Filter Press Chronic Pulsation Issues at Power Plant in Central PA Centrifugal Pump Startup Chemical Feed Cleaning Products Water Hammer in Wash-Water Header Pulsation Control in Hi-Temp Coffee Extraction Towers Waste Liquids Decontamination Label Adhesive Application Descaling Advanced Materials Facility Facilities Maintenance Paper Industry Diaphragm Life Pharmaceutical Solvent Drum Filling Line Chemical Transfer Deep Well Injection Coating Filtration Line Hydrochloric Acid Tank Truck Pharmaceutical Pulp & Paper Rocket Propellant Sewage Treatment Pump Startup & Shutdown Submarine Bilge Sump Storm Water Water Supply Waste Water