+49 (0)6181-424-7300 sales@blacoh.com

Job Stories

Click on a job story below to read more.
SUBMIT YOUR STORY
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.

Achieving Even Application of Screen Coating

Achieving Even Application of Screen Coating

Problem: A manufacturer producing coated screens for residential and industrial windows relied on air operated double diaphragm (AODD) pumps to deliver coating material to their screen coating machines. However, pulsations generated by the pumps caused the spray nozzles to apply an uneven coating across the screens.

This inconsistency led to quality issues and required re coating, increasing both material waste and production time. Compounding the challenge, the existing equipment layout provided no vertical installation space for a traditional pulsation dampener.

Reliable Rosin Size Dosing

Reliable Rosin Size Dosing

Problem: A pulp and paper facility required highly accurate and reliable rosin size dosing as part of its pulp treatment process. The application demanded precise chemical control to ensure consistent paper quality, while also providing uninterrupted operation in the event of pump maintenance or failure.

Given the critical nature of rosin sizing, the customer needed a fully integrated dosing system that could deliver accuracy and reliability throughout continuous operation.

Chemical Compatibility Diaphragm Failure

Chemical Compatibility Diaphragm Failure

Problem: A large manufacturing facility was using a polypropylene 5 gallon unit equipped with a PTFE (Teflon) diaphragm for a chemical application. The diaphragm material was initially believed to be compatible with the process fluid, but over time the chemical slowly degraded the PTFE, leading to internal wear and eventual leakage.

As the material deterioration progressed, leakage began occurring through threaded connections. Temporary fixes such as taping the threads were attempted but ultimately failed as the chemical continued to attack the diaphragm material.

The repeated leaks created reliability concerns and highlighted a material compatibility issue that had not been identified during the original selection.

View All Dosing Filling Water Hammer Spill Prevention Filter Metering Injecting Pulsation Dampening Spray Coating Transfer Inlet Stabilization
JOB STORIES
View All Modular, Skid Mounted Chemical Dosing System Pulsation Control in Hi-Temp Coffee Extraction Towers Water Hammer in Wash-Water Header Diesel Transfer Pump Transport of Copper Bearing Solution in Remote Mining Spill Prevention in Contact Lens Factory Label Adhesive Application Chronic Pulsation Issues at Power Plant in Central PA Chemical Process Leak in Boston Achieving Even Application of Screen Coating Reliable Rosin Size Dosing Chemical Compatibility Diaphragm Failure Pump Inlet Cavitation in Power Gen Facility Deionized Water Dosing in R&D Lab Pulsation in Sulfuric Acid Feed Deep Well Injection Aeration and Pulsation of Cleaning Products Filling Hose Failure due to Pulsation Filter Screen Damage from Pulsation Clogged Filters Causing False Gauge Readings Chemical Feed Injection Pulsation Low-Viscosity Injection Pulsation Oil and Gas Long Suction Vibration Diaphragm Pump Failures in Soup Can Manufacturing Diaphragm Failure Causes Repeated Spills in Paint Manufacturing Chemical Manufacturing Excessive Inlet Pressure Reciprocating Pump Pulsation in Power Plant Chemical Injection Pump Vibration Steel Manufacturing Descaling Pulsation Effect of Improper Dampener Application AODD Pump Pulled from Concrete Submarine Constrained Piping Acceleration Head Wastewater Transfer Pulsation Hazardous Waste AODD Containment Failure Paint Manufacturing Abrasive Slurry Diaphragm Failure Decontamination Facility Spray Pulsation Poultry Processing Diaphragm Pump Vibration Pharmaceutical Pump-Induced Pipe Vibration Aerospace Pump-Induced Pulsation Wastewater Sludge Transfer Pump Pulsation Wastewater Sludge Pump Pulsation Bottling Line Water Hammer Tool Manufacturing Manifold Startup Shock Commercial Restroom Flush Water Hammer Resin Plant Drum Filling Water Hammer Pharmaceutical Valve-Induced Water Hammer Hydraulic Transients in Pump Station Surge Causes Highway Shutdown Check Valve Backflow Water Hammer