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APPLICATIONS

Pumping System Solutions Across Multiple Industries

Chemical Process
Paint & Coating
Water Treatment
Biotech & Pharmaceutical
Food & Beverage
Gas, Oil & Petrochemical
Pulp, Paper & Textile
Consumer Products
Choose a category and a story to read more about the uncommon solutions we provide to common problems!

Submarine Bilge

Industry Served: Water Treatment

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.

SOLUTION:
A Blacoh SENTRY I Flat Top 175 cubic inch pulsation dampener was installed on the suction and discharge of the pump. The dampener has a rubber bladder to separate the pumped liquid from a compressed nitrogen charge. The gas charge in the dampener alternately compresses and expands as the pump cycles and allows the dampener to remove the sharp flow pulses, therefore eliminating any acceleration head and vibration from the pipe system.

RESULT:
Since the installation of the Blacoh dampeners, hose life was increased.

Power Plant

Industry Served: Gas, Oil & Petrochemical

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.

SOLUTION:
A Blacoh SENTRY III pulsation dampener was installed in the common discharge of two metering pumps to create smooth and consistent flow.

RESULT:
Hydrazine is now delivered to the boiler in a precise and consistent quantity. In addition, pipe vibration has been eliminated, gauge accuracy has been maximized, and pump component stress has been reduced.

Sewage Treatment 1

Industry Served: Water Treatment

PROBLEM:
The Maquoketa, Iowa sewage treatment facility uses a twin disc type reciprocating pump to transfer pretreated sewage sludge from a clarifier to a digester. The twin disc pump is ideal for this application because this type of pump has no valves that can clog or restrict flow. Each disc of the pump transfers about one gallon of liquid with each stroke. The reciprocating action of the pump causes the discharge pipe and other components in the system to vibrate. This constant shaking causes joint leakage and premature failure of instrumentation. Pipe support brackets have been pulled loose from the wall.

SOLUTION:
A Blacoh SENTRY 5 gallon pulsation dampener was installed at the discharge of the pump. The Blacoh dampener contains a rubber bladder inside to separate the sludge from a compressed air charge. The air charge in the dampener alternately compresses and expands as the pump strokes, and allows the dampener to act as a shock absorber and remove shaking from the pipe system.

RESULT:
Since the SENTRY 5 gallon pulsation dampener was installed, vibration in the system has been reduced, system pressure has stabilized, and no joint leakage or instrument failure has occurred.

Chicken Plant

Industry Served: Food & Beverage

PROBLEM:
Steggles Chickens of Newcastle uses a 4" electric diaphragm pump to transfer chicken waste from a wash-down sump to a centrifuge. The diaphragm pump is suited to the application because of its ability to handle large solids such as chicken heads and viscous sludge consisting of congealed chicken blood. The pump's reciprocating action created vibration in the piping system which caused damage to brackets, fittings and valves.

SOLUTION:
After trying various measures and seeking to source a different style of pump, a Blacoh SENTRY IV 5 gallon pulsation dampener was installed as a final resort. The dampener was installed directly at the pump discharge. This dampener had aluminum wetted construction with a Buna-N bladder.

RESULT:
The installation of the pulsation dampener solved the problem and reduced the pipework vibration. At one point, a pump diaphragm would be lucky to last one week. Now normal life expectancy is approximately six months. The system now operates correctly resulting in less down time and lower costs.

Pharmaceutical

Industry Served: Biotech & Pharmaceutical

PROBLEM:
A leader in the manufacturing of pharmaceuticals uses a Goulds 3196 centrifugal pump size 1x1.5-8 to transfer 35 gallons/minute of acetone at 30 psi from the tank farm into the clean storage room. There is an automatic actuating valve in the line that opens and shuts upon plant demand. This quick shutting valve is sending pipe hammer down the line and causing shaking of the pipes, leaks, pipe hangers pulled from the ceilings, and damage to the pump, resulting in costly, unwanted repairs.

SOLUTION:
A Blacoh SENTRY I steel flat top, chargeable dampener was installed near the quick closing valve. The Blacoh dampener contains a PTFE bladder to absorb the water hammer from the quick closing valve. The charged air in the dampener compresses and expands as the valve shuts and absorbs the shock so water hammer and vibration are not sent down the line.

RESULT:
Since the SENTRY I pulsation dampener was installed, the pipe hammer has been eliminated! No more pump problems or repairs, replacing pipe hangers, fixing leaks, and most importantly, no downtime has occurred.

Paper Industry

Industry Served: Pulp, Paper & Textile

PROBLEM:
A leading paper manufacturer located in Japan uses air operated double diaphragm (AODD) pumps to inject process chemicals into a mixing tank. The low viscosity of the liquid, less than 10 centipoises, makes the chemical in this particular application very susceptible to the reciprocating action of the pumps. This makes it extremely difficult to maintain any type of accuracy when introducing the chemical into the batch. As a result, the quality and consistency of the final product suffers.

SOLUTION:
The installation of a Blacoh inlet stabilizer at the pump's inlet and a Blacoh pulsation dampener at the pump's discharge create an even flow into the pump and a pulse-free pump discharge which creates a smooth, consistent, laminar flow of the process chemicals. This allows the system instrumentation to function correctly, increasing accuracy and producing a quality product.

RESULT:
Since the Blacoh SENTRY Inlet Stabilizers and Pulsation Dampeners have been installed, the surge in the system has been eliminated. The system produces a smooth, even discharge which allows the system to function properly, saving the company thousands of dollars in production costs.

Oil & Gas Drilling

Industry Served: Gas, Oil & Petrochemical

PROBLEM:
Chesapeake Operating, Inc., a major oil and gas drilling company headquartered in Oklahoma, uses a Hydra-Cell triplex diaphragm pump (3.5” stroke, 450 rpm max speed, 27 gpm max. flow rate, 4500 psig max. pressure) to pump saltwater (1.13 sg). The pump is located over 100 feet from supply tanks. The supply line comes out of the tank, goes underground across a driveway/parking lot for more than 100 feet, then up out of the ground into the inlet of the pump. While the pump operated adequately, the pump inlet gauge fluctuated +/- 7 psig and steel pipes next to the fiberglass supply tank vibrated so violently the customer was concerned the tank would rupture.

SOLUTION:
A Blacoh model J4040V, 5 gallon suction stabilizer was installed on the inlet side of the pump. Suction pipe vibration stopped and fluctuation on the inlet pressure gauge decreased to +/- 1 psig. The customer is very pleased.

Sump Storm Water

Industry Served: Water Treatment

PROBLEM:
The Park Royal Hotel in Sydney has two large Flygt submersible pumps which operate automatically to pump out storm water and seepage. The pumps are installed in a sump in the basement car park. When the pumps shut down due to low level in the sump, the backflow of the storm water still in the discharge line returned against the check valve at the pump's discharge. This caused severe pipe vibration and water hammer. The force was so great that the pipe, mounted on the basement ceiling with brackets and Ramset dyna-bolts, was dislodged, landing on expensive motor vehicles.

SOLUTION:
A Blacoh SENTRY 5 gallon surge suppressor was installed downstream of the check valve to absorb the pressure spike.

RESULT:
Since the installation of the Blacoh SENTRY surge suppressor, the discharge pipework has remained fixed and the unsettling vibration and noise in the pipe system is no longer noticeable.

Diaphragm Life 1

Industry Served: Chemical Process

PROBLEM:
A manufacturer of metal soup cans located in New Jersey uses (8) 2" air diaphragm pumps to transfer the product which is used to line the cans. The suction of the pump is attached to the bottom of a 35' tall tank. The air operated diaphragm pumps are fitted with expensive PTFE diaphragms. The diaphragms were failing prematurely which resulted in loss of product, excessive downtime, and expensive part replacement. Additionally, leakage was occurring at the pump's clamping bands and the pumps were noisy during operation.

SOLUTION:
After reviewing the pump's inlet conditions, it was determined that the 35' tanks created excessive inlet pressure. Air operated diaphragm pumps are not designed to handle high inlet pressure above the 10 psi maximum for PTFE diaphragms. This high inlet pressure also caused the pump's inlet valves to work harder to close which resulted in damaging pump vibrations and excessive noise. After explaining to the customer that a Blacoh Inlet Stabilizer installed at the pump inlet would cushion and absorb the pressure spikes created by the higher inlet pressure, he was still skeptical. Watching the Blacoh demonstration that was provided proved conclusively that the high inlet pressure was damaging the pump's diaphragm. A BLACOH model J2400T stainless steel inlet stabilizer was installed at the pump's inlet.

RESULT:
Flow into the pump is now smooth and pulse-free. Diaphragm life is much longer and pump operation noise is greatly reduced. They were so pleased that a second stabilizer was ordered.

Hazardous Waste

Industry Served: Chemical Process

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 stee; 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.

SOLUTION:
A Blacoh SPILLSTOP (model SPS-20) was installed on the outlet of each AODD pump. Although the company does preventive maintenance every six months to avoid critical failure because a diaphragm failure can occur at any time, the SPILLSTOP units prevented spills on the three separate occasions when pump diaphragms ruptured, containing the hazardous material and automatically shutting down the system. (The SPILLSTOP can also be configured to automatically turn on a standby pump and sound an alarm.)

RESULT:
The company has purchased six SPILLSTOP units year-to-date and is looking at other areas in the plant where hazardous spills can be prevented.

Pharmaceutical Solvent

Industry Served: Biotech & Pharmaceutical

PROBLEM:
The Boulder, CO Roche Pharmaceutical manufacturing facility uses a 3" air operated double diaphragm pump to transfer methylene chloride from an underground tank to various spots throughout the plant site. The diaphragm pump is ideal for this application because it creates enough vacuum to lift the methylene chloride 12' at an elevation of 5300' above sea level, even when outside temperatures reach 90-100°F. The reciprocating action of the pump causes the discharge pipe and other components in the system to vibrate and shift.

SOLUTION:
A Blacoh SENTRY IV pulsation dampener was installed at the discharge of the pump.

RESULT:
After the installation of the Blacoh pulsation dampener, the surge generated by the pump was eliminated, thus reducing the vibration and need for extensive system maintenance.

Water Supply

Industry Served: Water Treatment

PROBLEM:
A major producer of water treatment chemicals accessed their local water supply through a 3" PVC pipe with quick closing valves. When the desired quantity had been measured and the valve shut, a water hammer effect with pressure spikes that exceeded the PVC pipe's burst strength was created. The PVC repeatedly broke, causing the entire plant to be shut down for repair. In addition, since pipe failure occurred under a nearby highway, it also had to be closed.

SOLUTION:
A Blacoh SENTRY 10 gallon surge suppressor was installed on the pressure side of each quick closing valve to reduce water hammer pressure spikes.

RESULT:
The damaging water hammer pressure spikes are now absorbed, no pipes have ruptured, and the plant (and nearby highway) have had no downtime due to water hammer.

Pulp & Paper

Industry Served: Pulp, Paper & Textile

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.

SOLUTION:
A Blacoh SENTRY IV pulsation dampener was installed in the common discharge of the pumps to dampen these pulsations.

RESULT:
Pipe stress and mounting fatigue have been eliminated. Not only have the pumps not been ripped from their cement foundations, but the mill has experienced longer life from pump components such as diaphragms and ball valves.

Sewage Treatment 2

Industry Served: Water Treatment

PROBLEM:
The City of Colorado Springs WWTP uses Abel mechanical double diaphragm pumps to transfer sludge throughout their facility. The pump is ideal for their application due to the solids handling capability, and the fact that the pump is a positive displacement pump which allows the flow to be metered. The reciprocating action of the pump causes excessive pulsation in the discharge piping. The constant pulsation has caused broken pipes, failed gaskets, damaged valves, and has pulled pipe supports from foundations.

SOLUTION:
A Blacoh SENTRY I CT2620NF dome top 370 cubic inch pulsation dampener was installed at the discharge of the pump. The Blacoh dampener has a Neoprene bladder that separates the sludge from the compressed air charge. The pulsation dampener acts as a shock absorber on the system by alternately compressing and expanding its gas charge as the pump strokes. This reduces the surge in the system created by the pumping action.

RESULT:
Since the SENTRY I pulsation dampener was installed, the surge in the system has been dramatically reduced. Valve, pipe joint, and pipe support failure have been eliminated. Installation of Blacoh pulsation dampeners is now a standard practice for the City of Colorado Springs WWTP whenever an Abel pump is installed in their plant.

Drum Filling Line

Industry Served: Chemical Process

PROBLEM:
MeadWestvaco is a resin plant in Charleston, SC. They have a drum filling line that operates with an automatic filling arm. When a drum is filled an automatic valve closes which causes an extreme water hammer effect. All the pipes leading into the system shake so hard they have broken loose from the pipe stringers

SOLUTION:
We installed a Blacoh CT2420WF pulsation dampener right at the connection point where the flexible fill hose starts. Now each time the automatic valve closes the hose absorbs a portion of the water hammer and the dampener absorbs the remainder. Pipes have stopped shaking and remain in place with no broken stringers. Also, operators feel safe from any possible pipes breaking causing product to be spilled out.

Filter Press

Industry Served: Consumer Products

PROBLEM:
The Franklin Brine Treatment Plant uses a Wilden diaphragm pump to charge a filter press with brine water oil/sludge. When first charging the filter press with the diaphragm pump, the filter screens are clean and product flow is exceptionally fast. Because of the reciprocating design of the pump, product flow is pulsating. The pulsating flow produces pressure spikes which cause damage to the filter screens. The piping is CPVC plastic because the brine water is corrosive. The pulsating flow also causes vibration which results in leaky pipe joints.

SOLUTION:
A Blacoh pulsation dampener was installed in the system at the pump discharge outlet. The dampener uses a compressed air charge contained by an elastomer bladder to create a shock absorber effect that minimizes pulsation and produces a more laminar flow of brine water into the filter press.

RESULT:
After installing the Blacoh dampener, the filter screens on the press have shown no signs of damage on the inlet side of the press. Since product flow is now pulsation free, there have been no more leaks in the CPVC pipe joints.

Chemical Transfer

Industry Served: Paint & Coating

PROBLEM:
A major U.S. paint manufacturer uses 3” air operated double diaphragm pumps (AODD) in their tank farm to transfer ingredients to their paint blending process area. One of the main ingredients is titanium dioxide (TiO2) which is both high in specific gravity and very abrasive. The 3” AODD pumps sit at the bottom of holding tanks that are 25 feet tall. Pump inlet pressure is high and this combined with the characteristics of the TiO2 acts to shorten normal pump diaphragm life. When an unexpected diaphragm failure occurs, several thousand gallons of TiO2 can be lost because when a pump diaphragm fails, the TiO2 is pulled through the diaphragm on the pump’s suction stroke and then expelled out the air exhaust.

SOLUTION:
Blacoh was contacted by the paint company’s local pump supplier who recommended the installation of a Blacoh SPILLSTOP at each AODD pump in the tank farm. The SPILLSTOP, which is pneumatically operated, is a spill containment devise that attaches to an AODD pump at its air exhaust. When a pump diaphragm fails, liquid is expelled out the pump’s air exhaust. The expelled liquid is contained in the SPILLSTOP unit, which then automatically shuts the pump off and sends a pneumatic pump failure signal. Since the SPILLSTOP is pneumatically operated, it is safe around hazardous and/or inflammable liquid.

RESULT:
After the SPILLSTOP units were installed, an estimated 3,000 gallons of TiO2 was saved when a pump diaphragm failure occurred. Not only was a product spill prevented, the investment in the SPILLSTOP was more than returned in saved cleanup costs alone.

Centrifugal Pump Startup

Industry Served: Consumer Products

PROBLEM:
An internationally known tool manufacturer located in the Pacific Northwest was experiencing severe pipe vibration in an overhead manifold system. The system delivers coolant to several production grinding machines. The coolant is delivered to the manifold by a 300 gpm centrifugal pump located in a reservoir on the plant floor. When the pump is started, a ball valve at the pump discharge is opened and fluid is pushed vertically up to the horizontal manifold. The manifold does not stay filled with liquid during idle periods so, when the pump is started the coolant flowing into the manifold must first push the air trapped in the manifold out the machine coolant nozzles before coolant reaches the machines. Since air moves more quickly out of the nozzles than liquid, when the coolant reaches the nozzles the velocity of the coolant is instantly reduced and a water hammer effect occurs creating severe pipe vibration.

SOLUTION:
A Blacoh 5 gallon surge suppressor was installed at the coolant pump’s discharge. The suppressor absorbs most of the initial energy generated at pump startup and then acts as a shock absorber as the water hammer shock travels back down the pipeline to the pump.

RESULT:
Since the Blacoh surge suppressor was installed, virtually all pipe vibration has been eliminated. The potential for pipe failure due to vibration has been minimized and worker safety has been greatly improved. A periodic check of the surge suppressor’s gas charge is all that is required to maintain trouble-free operation of the surge suppressor.

Deep Well Injection

Industry Served: Gas, Oil & Petrochemical

PROBLEM:
Hydroplex HP-350 triplex plunger pump (0.75 gpm at 10,000 psi) for high pressure deep well methanol injection in an oil & gas upstream pumping application. On the discharge side of the pump, the amount of methanol the pump is dosing is metered. Without a dampener to control pulsations and smooth out the flow, the installed flow meters will not give accurate readings. Additionally, when using a triplex pump it is important that all three chambers of the pump stay full of fluid with no voids. Any voids or pockets can cause seals to leak, pump vibration and excess pump noise.

SOLUTION:
A 12 cubic inch 10,000 psi SENTRY XPX model pulsation dampener was installed at the pump discharge to smooth out the flow and remove any pressure pulsations thus, allowing the dosing to be more accurate. An 85 cubic inch SENTRY inlet stabilizer (suction dampener) was installed on the inlet side of the pump to act as an accumulator to keep the pump chambers filled. The inlet stabilizer dampener also removes pulsations created by the pump on its inlet stroke.

Chemical Feed

Industry Served: Water Treatment

PROBLEM:
Japan Machinery Company, a manufacturer of water treatment equipment, uses air operated chemical feed pumps to inject various chemicals and additives at very high pressures. The reciprocating action of the pumps produced excessive pulsation and vibration in the discharge pipes of the system, which caused broken pipes, failed gaskets, damaged valves, and pulled pipe supports from their foundations.

SOLUTION:
A Blacoh high pressure SENTRY I model H2620A dome top 370 cubic inch pulsation dampener was installed at the discharge of the pumps. The Blacoh dampener has an Aflas bladder for chemical compatibility. By alternately compressing and expanding the compressed air charge within the dampener as the pump strokes, a shock absorber effect is created. This reduces the surge in the system created by the pumping action.

RESULT:
Since the SENTRY I pulsation dampener was installed, the surge in the system has been dramatically reduced. Valve, pipe joint, and pipe support failure have been virtually eliminated. Installation of Blacoh high pressure pulsation dampeners is now standard on most new systems.

Diaphragm Life 3

Industry Served: Chemical Process

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.

SOLUTION:
A Blacoh distributor was asked to find a solution to the rapid diaphragm failure problem. After consultation with Blacoh, a decision was made to install a 5 gallon Blacoh SENTRY inlet stabilizer at the inlet to each AODD pump. The inlet stabilizer acts as a shock absorber to cushion the water hammer pressure spikes created as the pump’s inlet valves rapidly open and close. The SENTRY inlet stabilizer uses compressed air, separated by a PTFE diaphragm from the process fluid, to balance pump inlet pressure and provide a smooth and continuous flow of liquid to the pump.

RESULT:
After SENTRY inlet stabilizers were installed, pump diaphragm life was extended from hours to more than 6 months. The SENTRY inlet stabilizer paid for itself in the first two weeks of operation.

Coating Filtration Line

Industry Served: Paint & Coating

PROBLEM:
A painting operation for a skid manufacturer in North Carolina uses a large quantity of bag filters throughout the paint line to filter rinse water and various coatings and paints. Paints and coatings were clogging the gauges causing the gauges on the bag filters to give false readings. The incorrect gauge readings led to poor filtration, due to infrequent bag changes, and manufactured parts were getting rejected in QC.

SOLUTION:
50 Blacoh SENTINEL gauge guards were installed on the bag filters to isolate and protect the gauges from the process fluids. With gauges now giving accurate readings, bags are changed out properly to insure proper filtration and QC is no longer rejecting manufactured parts.

Hydrochloric Acid

Industry Served: Chemical Process

PROBLEM:
Using a reciprocating diaphragm pump creates a turbulent product flow which causes excess vapors and product aeration.

SOLUTION:
Installing a Blacoh surge dampener on the discharge port of the pump creates a smooth, even and consistent flow similar to that of a centrifugal pump.

RESULT:
The use of a Blacoh dampener helped eliminate excessive vapors in the storage tanks during transfer of acid from tank to tank and also eliminated pipe vibration on the long runs of discharge pipe to the top of the tanks.

Chemical Feed

Industry Served: Consumer Products

PROBLEM:
MID South Wire Co., Inc. in Nashville, TN uses Yamada Air Operated Double Diaphragm Pumps to supply the feed of sulfuric acid to the centrifuge which is a continuous process and requires as smooth and even a flow rate as possible. The double diaphragm pump was giving good service but, the customer either had to change out the pump for one with continuous flow or find a solution for the pulsating flow.

SOLUTION:
A Blacoh 1" Polypropylene unit with PTFE bellows was recommended to the customer. The customer purchased the unit and installed it. He was very pleased with the quality of the flow conditions out of the pump after the pulsation dampener was installed. The customer has since purchased another unit for a similar application.

RESULT:
First of all, a happy customer. We solved his problem with the help of a Blacoh pulsation dampener. The customer could not believe the results and will use and recommend Blacoh to his other plants to solve pulsation problems.

Cleaning Products

Industry Served: Paint & Coating

PROBLEM:
Pumping household cleaning products such as oven cleaner, furniture polish, floor waxes, and starch. After blending of various chemicals to manufacture the final products, the product is pumped into various holding tanks within the plant. During this process the product travels through long lengths of piping to various filling locations. Foaming and aerating of the various cleaning products created a problem with the filling process of aerosol cans. Also, due to the long lengths of piping, the pumping action of the diaphragm pump created pipe vibration and potential leaks at fittings.

SOLUTION:
By installing a Blacoh pulsation dampener in line on the discharge of the pump, the foaming and frothing of the pumped household cleaning products was eliminated.

RESULT:
With the introduction of the pulsation dampener, the amount of time required for the product to settle in the holding tanks was reduced.

Pump Startup & Shutdown

Industry Served: Water Treatment

PROBLEM:
AGI Industries was contacted by a local construction company doing the construction on the West Closure Complex Pump Station in New Orleans, Louisiana. This is one of the largest pumping stations in the United States and is part of the Hurricane Protection Project. During heavy storm conditions, including hurricanes, pumps can inadvertently shut down due to power failure. Pumps will also quickly turn back on when power is restored. When this sudden start/stop of the pump occurs, fluid in the system will change velocity rapidly and can actually reverse direction. New incoming fluid can collide with this reverse flow as the pump restarts. This event causes a severe water hammer effect that can damage piping, valves, and the pumps.

SOLUTION:
Blacoh surge tanks were installed at various locations in the pumping station so that when the pumps shut down/restart the water hammer spike is captured in the vessels and no damage occurs to the system. Due to space constraints within the system, Blacoh designed special custom legs for the surge tanks/suppressors that mount to the pump station ceiling. Also, on the vertical surge suppressors, Blacoh provided special mounting brackets to allow for easy installation and support.

Waste Liquids

Industry Served: Gas, Oil & Petrochemical

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.

SOLUTION:
The installation of Blacoh pulsation dampeners removed the pulsation from the lines reducing the noise to acceptable levels.

RESULT:
Reduced sound levels equate to happier workers.

Tank Truck

Industry Served: Chemical Process

PROBLEM:
Blacoh was contacted by a large manufacturer of bulk chemicals. They use air operated diaphragm pumps (AODD) to load chemicals into tanker trucks through a 20' flexible 3" reinforced hose that lies on a concrete floor. The pulsation generated by their AODD pumps caused the hose to shake back and forth, scuffing the hose on the concrete floor and causing "hose abrasion". Ultimately, these hoses would fail from abrasion due to the scuffing action. This failure meant considerable downtime, lost product, extensive cleanup, and hose replacement, all of which came with an associated cost.

SOLUTION:
Blacoh installed a SENTRY 5 gallon pulsation dampener at the discharge of each of the 3" AODD pumps. The dampener absorbed the pulses generated by the pump and the flow from the pump is now smooth and steady.

RESULT:
The hose no longer shakes and scuffs on the concrete floor. Since the installation of the Blacoh pulsation dampeners, not a single hose has been replaced due to abrasion failure. The investment in pulsation dampeners has paid for itself several times, in both time and cost savings.

Decontamination

Industry Served: Paint & Coating

PROBLEM:
A decontamination facility pumped acids and water through a series of 15" spray nozzles to rinse radiation from contaminated metals. However, the pulsating action of their reciprocating pumps caused uneven spray into the rinse tanks, and the metals were not rinsed completely.

SOLUTION:
A Blacoh SENTRY I pulsation dampener was installed at each pump discharge manifold to eliminate the surging flow of the pumps and ensure complete coverage and thorough cleaning.

RESULT:
The even flow ensures that the metal product is completely rinsed of radiation. Furthermore, both process time and the amount of acid required were reduced, which increased productivity and profit.

Rocket Propellant

Industry Served: Gas, Oil & Petrochemical

PROBLEM:
A nationally recognized leader in the manufacture of solid rocket propellant uses air operated double diaphragm (AODD) pumps to transfer a particularly aggressive fluid to a unique piece of equipment that requires a constant and steady flow. The reciprocating action of the pump causes excessive pulsation in the discharge piping. Constant pulsation causes erratic flow which prevents the pumps from performing as required.

SOLUTION:
A Blacoh SENTRY pulsation dampener was installed on the discharge of each of the AODD pumps.

RESULT:
The installation of the Blacoh SENTRY pulsation dampener on the discharge of each pump allowed the fluid to flow smoothly and with little to no fluctuation. This greatly improved the flow at 120 GPM through the piping into the 500 gallon supply tank.

Waste Water

Industry Served: Water Treatment

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.

SOLUTION:
A Blacoh SENTRY II plastic flat top pulsation dampener was installed on the discharge line after the Wilden air operated double diaphragm pump. The Blacoh dampener acts as a shock absorber as the air charge in the dampener alternately compresses and expands as the pump pulses. This eliminated the vibration and pulsation through the PVC line.

RESULT:
Since the SENTRY pulsation dampener was installed, everything is running well, no leaks have been found and no down time has been reported.

Descaling

Industry Served: Consumer Products

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.

SOLUTION:
A Blacoh 2.5 gallon high pressure pulsation dampener with 4" raised face flanged connection was installed on the discharge of each pump. The Blacoh dampener contains a rubber bladder that separates the fluid from a compressed air charge, and acts as a shock absorber for the system by alternately compressing and expanding as the pump strokes. A Blacoh CT4440N inlet stabilizer was installed at the inlet of each pump to produce a smooth flow of fluid to the pump.

RESULT:
With the addition of both the Blacoh pulsation dampener and inlet stabilizer, the system performed flawlessly. The steel mill was able to achieve uniform descaling of their raw material as well as eliminate severe shaking in the system. The inlet stabilizer allowed the pump to operate smoothly without any effects of cavitation. This system has been in operation for over two years without any major problems.

Diaphragm Life 2

Industry Served: Chemical Process

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.

SOLUTION:
A Blacoh SENTRY inlet stabilizer was installed on the inlet side of the pump to cushion and absorb the water hammer spikes created when the pump's inlet ball valves close. When the pressure spikes are cushioned, the effect of high acceleration head is diminished and the stress is removed, resulting in increased diaphragm life.

RESULT:
The Blacoh inlet stabilizer has been installed for over one year. In that time, the pump has not had a diaphragm failure and additional units have been installed on other AODD pumps in the tank storage area.

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