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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.

AODD Pump Pulled from Concrete

AODD Pump Pulled from Concrete

Problem: A major pulp and paper mill in the Northwest used AODD unloading pumps. The reciprocating action of these air operated pumps created violent pulsations that caused both pipe stress and mounting fatigue. In fact, these pulsations often caused the pumps to be pulled from their cement foundations. This created significant downtime, costly foundation repair, environmental hazards, and a dangerous working environment.

Submarine Constrained Piping Acceleration Head

Submarine Constrained Piping Acceleration Head

Problem: The Australian Submarine Corp (ASC) uses a 32mm peristaltic hose pump in Collins Class Submarines to transfer oily contaminated seawater from the bilge to the waste tank. The peristaltic hose pump is perfectly suited to the duty because the pump is capable of self-priming, dry running indefinitely, and can handle sludge-type materials that could be encountered in the bilge. The overall physical size of the pump coupled with the cramped internal confines of the submarine resulted in the suction and discharge pipe work being considerably twisted; incorporating many bends and valves. The pulsed flow action caused the acceleration head of the pump to sharply increase and markedly decrease hose life to the extent that offshore trials were lasting less than a week.

Wastewater Transfer Pulsation

Wastewater Transfer Pulsation

Problem: Vishay Measurements Group uses a Wilden 1" Air Operated Double Diaphragm pump to pull the plants processed waste water out of a pit and pump it over to the waste water plant to be processed. The reciprocating action of the pump caused pulsation in the PVC discharge pipe which caused the system to vibrate. The continuous shaking of the PVC pipe caused joints to break apart and stress caused cracking in the discharge pipe.

Hazardous Waste AODD Containment Failure

Hazardous Waste AODD Containment Failure

Problem: A major chemical company in Michigan uses air operated double diaphragm (AODD) pumps for unloading hazardous waste, including many different chemicals and products (e.g., acids, solvents, methyl chlorides, etc.). Each of the AODD pumps are 2 inch stainless steel; with PTFE internals, and are pumping at a flow rate of 80 to 100 gpm at 30 psi discharge pressure. The company has experienced pump diaphragm failure due to the elastomer material wearing out or damage from metal particles. When a diaphragm fails, the product goes into the air system and then out through the pump’s air exhaust. Because the product is hazardous, there is zero tolerance for spills. If a spill occurs, HAZMAT is called and the cost of cleanup can range from $20,000 to $100,000 depending on severity.

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 Flotation Reagent Dosing System Reliable Tailings and Concentrate Sampling Rare Earth Mineral Recycling 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 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 Classic Pulsation Dampening in Peristaltic Hose System Check Valve Backflow Water Hammer