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Diesel Transfer Pump

Diesel Transfer Pump

Problem: The diesel transfer pumps on an offshore platform had never operated reliably or automatically since installation. This forced operators to transfer diesel to the electrical generators manually, resulting in significant delays and safety risks.

Chronic issues included:
• Recurring diaphragm ruptures
• Diesel leakage at the muffler
• Hose failures
• Excessive vibration in pump and piping
• Frequent instrument damage (pressure transmitters, PSVs, filter elements)
• Low and inconsistent transfer pressure
• Extremely long transfer times (6–8 hours for a 30% fill)

Root Causes Identified:
1. Pump suction pressure significantly exceeded recommended limits, producing severe water hammer effects and subjecting PTFE diaphragms to damaging pressure spikes.
2. Process air regulator pressure was set too high, further increasing pressure peaks and accelerating failures.
3. The original pump design lacked necessary stabilizing accessories to control pulsation and protect downstream components.

Transport of Copper Bearing Solution in Remote Mining

Transport of Copper Bearing Solution in Remote Mining

Problem: A mining facility in Chile required a reliable and flexible solution to recover and transport copper-bearing solution just over 2 miles (3.5 km), from the leach pad to the process ponds. The operation had to be performed in a harsh, remote environment with no fixed infrastructure, while minimizing pressure losses and allowing the system to be easily relocated based on operational needs.

Spill Prevention in Contact Lens Factory

Spill Prevention in Contact Lens Factory

Problem: A highly sterile production facility manufacturing liquid materials for contact lens production experienced a critical failure of an air operated diaphragm pump. The pump’s diaphragm ruptured, causing the expensive chemical product to spill across the floor. Beyond the immediate material loss, the incident created contamination risks in a controlled cleanroom environment and exposed the process to costly downtime.

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.

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.

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.

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