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Diaphragm Failure Causes Repeated Spills in Paint Manufacturing

Diaphragm Failure Causes Repeated Spills in Paint Manufacturing

Problem: A nationally recognized manufacturer of quality paints uses air operated double diaphragm (AODD) pumps in process and transfer applications. In this application, the AODD pumps are used in a tank storage area to transfer Texanol, a solvent-based paint additive, to the production facilities within the plant. The AODD pump sits at the bottom of a 20' high Texanol storage tank. The inlet ball valves of the pump open and close several times per second. Each time the ball valve is closed or "seated", the fluid velocity is abruptly stopped. This creates high pressure spikes or "water hammer". The force of the spike severely weakens the integrity of the PTFE diaphragms by distorting their shape with unbalanced pressure loads and concentrating stress onto one area of the diaphragm, causing cold flow. The diaphragms were lasting only three weeks before failure. Every time a diaphragm failed, production halted and solvent was spilled into the containment dike and lost.

Chemical Manufacturing Excessive Inlet Pressure

Chemical Manufacturing Excessive Inlet Pressure

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.

Reciprocating Pump Pulsation in Power Plant

Reciprocating Pump Pulsation in 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.

Chemical Injection Pump Vibration

Chemical Injection Pump Vibration

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.

Steel Manufacturing Descaling Pulsation

Steel Manufacturing Descaling Pulsation

Problem: Rocky Mountain Steel Mills in Pueblo, CO uses two Myers/Aplex MA-240M quintuplex 200 HP plunger pumps to descale the raw material before it is sent through the forming rollers that create the final product. Each of these pumps produces 100 GPM at 2,200 psi. The reciprocating action and high pressure created by these pumps causes severe shaking of the pipes, valves, and pipe supports in the system. More critical to the operation, the pulsating flow can cause erratic descaling of the raw material. This erratic descaling can cause damage to the form rollers and can make it difficult for the steel mill to achieve consistent quality in their final product. This style of pump also requires a smooth flow of fluid to the inlet to work properly.

Effect of Improper Dampener Application

Effect of Improper Dampener Application

Problem: An advanced materials facility based in the Greater Toronto Area was hesitant to include dampeners in their operation as they hadn't had luck with them previously. Blacoh asked to see the installation. Upon further investigation, we discovered the customer had one uncharged dampener for two pumps (photo below), and it was located well outside the recommended 10 pipe diameter rule. This is a prime example of the importance of Size, Location, and Charge in regards to dampener installation.

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