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Power Plant

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.

Chicken Plant

Chicken Plant

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.

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.

Oil & Gas Drilling

Oil & Gas Drilling

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.

Hazardous Waste

Hazardous Waste

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.

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.

View All Dosing Filling Water Hammer Spill Prevention Filter Metering Injecting Pulsation Dampening Spray Coating Transfer Inlet Stabilization
JOB STORIES