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Deionized Water Dosing in R&D Lab

Deionized Water Dosing in R&D Lab

Problem: As it is a system with 8 units, the deionized water requirement can range from one unit at a time to all 8 simultaneously. The pump pulse was damaging the flow sensors, and the pressurized line was disrupting the solenoid valve cycle. When the water requirement was low or from only one unit, the pump tended to shut down.

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.

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.

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.

Pulsation in Dual Hose Pump Application

Pulsation in Dual Hose Pump Application

Problem: A systems integrator in Pennsylvania was building a new lime slurry storage and transfer silo for an end user in Georgia. The system included two 35 mm peristaltic hose pumps operating in a challenging lime slurry application.

Historically, the integrator did not always include pulsation dampeners on these types of builds, which had led to past issues with inconsistent pump behavior. For this new project, two pulsation dampeners were added to improve reliability. During system testing, however, one of the dampeners failed, creating concern around schedule impact and readiness for shipment.
With the silo build nearing completion and the delivery date approaching, the issue needed to be resolved quickly to avoid delays to the end user.

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