Flexible diaphragms provide solutions

4 May 2021
FacebookTwitterLinkedIn மேலும்

Diaphragm manufacturer Gottlob Dietz benefitted

from using Saint-Gobain Flex Barriers, further increasing diaphragm reliability and lifetime for their

global customers. (Image: Shutterstock) The Ariane

Group encountered diaphragm rupturing problems with its Ariane 5 programme, which were solved by
Saint-Gobain’s Flex Barriers. (Image: Shutterstock)
There has been significant growth in pumps that employ diaphragms as many industries
recognise the contribution these pumps can make to process engineering. Here, we examine
how flexible barrier materials for diaphragms can solve challenges faced by AODD and
dosing/metering pumps.

Air-operated double diaphragm (AODD) and dosing/metering pumps are two very different types of
positive displacement pumps, but what they have in common is the use of diaphragms. Whereas the
AODD pump is generally used for the transfer of higher volume liquids, the dosing/metering pump has
its niche in the continuous in-phase metering of single or multiple liquid systems at varying flow rates. 

The growth in demand for mechanically coupled and hydraulically actuated diaphragm pump heads can
largely be attributed to the development of materials suitable for diaphragms. Thermoplastic elastomers
(TPE) and Polytetrafluoroethylene (PTFE) synthetic materials used in the manufacture of diaphragms
have opened up new opportunities for AODD and dosing/metering pumps. For both pump types it is
essential that the diaphragm material is compatible with the fluid being pumped and that it is flexible at
low temperatures and does not deteriorate at high temperatures and pressures. 

AODD pump diaphragms

Over the past half century, the AODD pump has evolved to become a proven technology for the
complex fluid transfer needs encountered across many industries. The pump’s reputation is built on the
technology’s ability to handle a wide range of liquids with varying characteristics. With the AODD pump
it doesn’t matter if the fluid is thick, thin, particle-free or in the form of slurry. The pump’s design allows it
to pull in the liquid, regardless of its composition, and drive it downstream. 

The importance of the diaphragms in an AODD pump cannot be over-estimated; if they fail, then so
does the pump. Using compressed air to act upon the diaphragms, the liquid media is pulled into the
pumping chamber and then ejected, without the use of rotating parts. When running, the only dynamic
components that come into contact with the fluid are the two diaphragms which are connected by a
common shaft, the two inlet valve balls and the two discharge valve balls.

The diaphragms act as a separation membrane between the compressed air supply and the fluid.
Driving the diaphragms with compressed air balances the load on the diaphragm, thereby removing
mechanical stress and extending diaphragm life. The valve balls open and close on the valve seats to
direct the flow. 

The AODD pump can be used at every stage of the liquid transfer production cycle, from off-loading raw
ingredients from tankers to transporting semi-processed and processed product around the plant. The
pump offers the ability to handle shear-sensitive fluids, keep thick and viscous fluids constantly flowing
and provide leak-free operation.

Material selection
Correct diaphragm material selection is critical to ensure safe pump operation. The primary factors to
consider when choosing diaphragm materials are chemical compatibility, temperature range, abrasion
resistance, flex-life, performance, sanitary standards, resistance to cleaning fluids, particle build-up on
the diaphragm surface, suction lift, efficient performance and cost. To help meet these diverse
operational criteria, the number of effective diaphragm materials has grown.

Diaphragms are the hardest worked components in an AODD pump and can be expected to work for up
to 10,000 hours before needing to be replaced. It’s a tough call because the desired flexibility of the
diaphragms has to be maintained throughout their operating life in order for the pump to operate
effectively on start-up. 

Achieving maximum mean time between failures (MTBF) must be a priority in selecting a diaphragm,
which means matching the diaphragm materials to the fluid being pumped and the pump’s operating
conditions. Materials that offer a long flex-life provide predictable performance, enabling planned
maintenance and membrane replacement. In many situations AODD and also dosing/metering pumps
are open to the elements, so the diaphragms must be able to withstand extreme temperatures.
Diaphragms challenges
Both AODD and dosing/metering pumps can be found operating in a diverse range of industries and
each industry will pose its own set of challenges. That said, regardless of the industry they all have
common requirements that must be met. Operators need their pumps to be in a state of readiness when
called upon during the production cycle and to provide smooth, leak-free, and accurate pumping,
coupled with low maintenance. If these basic requirements are not met, then there will be the inevitable
adverse impact on the efficiency of the production line.

Pump downtime, loss of product, product contamination and frequent replacement of components, all
result in high running costs and lifetime cost of ownership. These issues often lead to production delays,
dissatisfied or lost customers, reduced capacity and impact the bottom line.

The challenges posed by industries such as foodstuffs, pharmaceuticals and personal care products
can differ considerably from those in wastewater, paints and coatings, and chemicals. Surfaces must be
compatible with all relevant industry standards, ultra-smooth to ensure a smooth flow, crevice-free to
avoid any solids becoming trapped, not prone to cracking and be suitable for liquids used in clean-in-
place procedures. Any break-up of the diaphragm surface has the potential for cross-contamination of
the pumped media. Where foodstuffs are being pumped, the possibility of the media shearing or splitting
and its potential to adhere to the diaphragm surface will always be considerations. 

In chemical processing and where aggressive or hazardous materials are involved, the pumped media
can be of a very low lubricity and therefore abrasive. These problems will challenge the perm- eability of
the surface and result in potentially harmful vapours or volatile organic compounds damaging pump
components and leaking to the atmosphere.

Saint-Gobain
Given the extensive list of factors that will influence the performance of diaphragms, it is easy to come
to the conclusion that it is a problem which many industries have to accept. However, that’s not the
case.  Significant advances in the development and refinement of existing materials mean that pump
users can overcome the challenges set out above and achieve efficient production that improve
operational efficiencies and the bottom-line profit. 

Saint-Gobain Films & Fabrics has been at the forefront of the development of flexible barriers for
diaphragms that have been shown to challenge and solve the issues discussed. In certain applications,
increases in flex cycles and lifetime have been up to 70% higher than regular modified PTFE and
vapours’ permeability was reduced by 30%.

“In developing our flexible barrier materials, Saint-Gobain Films & Fabrics have concentrated on the
issues that impair diaphragm performance, the results being products that increase MTBF, improve
productivity and extend pump working life through greater reliability,” explains Frank Sonnenschein,
Business Development Europe.

“Compliance to all relevant international standards has been a priority in the development of Flex
Barriers and developing the range of industries served. Our Flex Barriers have practically universal
resistance to chemicals and highly aggressive media such as aromatic or chlorinated hydrocarbons,
acids, caustics, ketones and acetates.”

Flex Barriers
Resins used to produce Saint-Gobain’s Flex Barriers conform to the major regulations critical to success
in pharmaceutical, food and beverage, sanitary and medical applications. These include: FDA21
CFR177.1550, (EC) No.1935/2004, (EU) No.10/2011, (EC) No.23/2006 (GMP), USP Class VI and 3-A
Sanitary Standard. In addition, the materials conform to REACH (EC) No.1907/2006 and RoHS
(2011/65/EU) regulations, so they do not contain any hazardous or banned comp-ounds that would
restrict the materials used in products.

Available in different constructions, as single layer film or laminated composites, Flex Barriers are based
on high quality raw materials. Saint-Gobain Films & Fabrics uses specialised surface treatments and a
proprietary process to impart high flex life, low permeability, high smoothness and a low coefficient of
friction in its Flex Barriers. The resulting products can be thermoformed by customers to produce a
diaphragm to their required size. 

The sodium ammonia etched barrier film can be bonded to the customer’s carrier diaphragm (typically
rubber) and from there thermoformed and vulcanised, usually in a single operation. Alternatively, the
PTFE barrier can be pre-formed prior to vulcanization. The Flex Barriers are available to pump
diaphragm manufacturers in rolls or sheets suitable for stand-alone diaph-ragm components. With
special surface treatment, the films are designed for high-integrity bonding to rubber-backed
diaphragms.

Problems solved
PTFE rupture, a major cause of diaphragm premature failure, has been solved by the exceptional flex-
life performance of Saint-Gobain’s Flex Barriers. “An often under-appreciated benefit of these Flex
Barriers is their gradual mode of failure as opposed to catastrophic, which means the sites have a
chance to organise maintenance/ replacement in a planned manner rather than having to deal with a
sudden “line shutdown” and material losses,” explains Frank Sonnenschein. Furthermore, diaphragm
delamination resulting from poor and in-consistent bonding of PTFE and rubber as well as damaging
media permeation has been eliminated. The result is excellent durability with a significantly reduced
stretch void index. 
Contamination attributable to a diaphragm’s rough surface has been eliminated by the smooth inert
surface of the barrier. In addition, for deep drawing manufacturing issues, where the problem’s root
cause is stiff and heterogeneous material, the high quality and flexibility of these barrier films removes
causes for concern.

Application success
Diaphragm manufacturer Gottlob Dietz has benefitted from using Saint-Gobain Flex Barriers, having
managed to further increase diaphragm reliability and lifetime for its global customers. In order to
decrease the risk of failures resulting from disc rupture and delamination between PTFE and rubber
backing on pharmaceutical dosing pumps, Gottlob Dietz switched to the new Flex Barriers. It increased
the flexibility and lifetime, demonstrated improved resistance to permeability and greater bonding
strength with the rubber backing. 

Diaphragm rupturing during thermoforming, chemical resistance to rocket fuels and permeation were
problems that the Ariane Group encountered in its Ariane 5 space programme. “These problems
affected the entire programme not only due to costs but mainly to safety reasons,” explains Frank
Sonnenschein. “Working together, we solved these problems through the co-development of a multi-
layer fluoropolymer laminate solution.” 

Using this product Ariane resolved the safety issue, enabling the rocket to enter space with a more
effective fuelling system. Through this cooperation Saint-Gobain Films & Fabrics has established that
higher levels of formability than ever imagined are now possible. Furthermore, the mechanical
robustness of these materials opens the door to even substituting steel diaphragms to reduce pump size
and costs. 

For further information, please contact:

Frank Sonnenschein, Business Development manager, Saint-Gobain Films &
FabricsFrank.Sonnenschein@saint-gobain.com
Tel: +49 (1525) 7438915

Atlas Copco's PAC H high head pumps reduce

MTTR
11 May 2021
FacebookTwitterLinkedIn மேலும்
 Access to the pump hydraulics is ensured with an
innovative hinge kit, compromising a ‘swing door’ that allows quick and easy access to the pump’s

internal workings. High head pumps are the

workhorses of many industrial fluid control systems, so it is vital that the pump operates reliably for

extended periods of time. Atlas Copco has focused on

improving pump and seal design to increase MTTR and reduce the time and cost associated with pump
maintenance.
In developing its new breed of high performance, heavy duty PAC H pumps, Atlas Copco has
focused on improving pump and seal design to increase MTTR and reduce the time and cost
associated with pump maintenance.

High head pumps are the workhorses of many industrial fluid control systems. Their role can often be
mission-critical, particularly in settings such as water transfer in the oil & gas sector, municipal water
treatment and supply, and dewatering applications in construction and mining, where the control and
removal of surface water is a primary safety concern.

In such applications, it is vital that the pump operates reliably for extended periods of time. Maintenance
outages need to be kept to a minimum: both in terms of the mean time to repair (MTTR) and the length
of time required to complete any necessary repairs or servicing. Any unexpected outages due to the
failure of a seal, or premature corrosion of the impeller, for example can have serious consequences,
impacting on productivity, operational efficiency, operational safety and therefore on profitability.

Problems with pumps

However, maintaining high head pumps can be challenging. The uses to which these pumps are put
mean that they are often located in cramped and/or remote environments and spend much of their time
submerged. As a result, there are few opportunities for visual inspections which would spot early signs
of sub-optimal performance, such as excessive vibration or unusual wear and tear.

On top of these adverse operating conditions, the design of the pump itself must be considered. To
perform effectively, a pump needs to be built for maximum flow and minimal leakage. However, the
robust outer casing can mean that hydraulic elements are difficult to access, reducing maintenance
efficiency.

Of course, some breaches in the outer casing are integral to pump design: for example, where the
impeller shaft enters the pump housing. Here, a mechanical seal is introduced to preserve the integrity
of the pump by preventing fluid leaks and keeping contaminants out. 

The downside is that mechanical seals have maintenance requirements of their own. A mechanical
seal can easily leak or become damaged if the pump is allowed to run dry. Incorrect installation, or
failing to clean the areas surrounding the seal, can also lead to premature failure.

As part of its development strategy toward its new breed of high performance, heavy duty PAC H
pumps, Atlas Copco focused on improving pump and seal design to increase MTTR and reduce the
time and cost associated with pump maintenance.

Design improvements
The issue of ready access to the pump hydraulics has been addressed with development of an
innovative hinge kit. This comprises a ‘swing door’ that allows quick and easy access to the pump’s
internal workings. Ease of maintenance is further enhanced with the use of a single bolt to remove the
impeller. Bolted wear rings make for precise and simple replacement compared to pressed alternatives,
and link belts are used to enable changeovers without having to dismantle the entire wet end of the unit.

The semi-cartridge seal design on the PAC H pump comes as standard, allowing seal access and
replacement from the front. Atlas Copco’s SEAL design allows changeout without dismantling the pump
and makes the lip seal and impeller easily accessible via reducing downtime and simplifying
maintenance. An integral seal oil bath prevents damage if the pump runs dry, while a visual inspection
port makes leakage inspection simple.
To prolong pump operational life and protect the seal, Atlas Copco has developed a closed impeller that
is equipped with deflector vanes. This provides two benefits: it improves thrust balance on the shaft and
impeller to minimize wear and keeps the mechanical seal clean. Essentially, the vanes create a vortex
that prevents the accumulation of detritus. This helps the mechanical seal last three times longer.
Moreover, it eliminates the need to use flush water to keep the pump clean: offering significant energy
and cost savings over the pump’s operational lifetime.

To further support minimal downtime through more efficient maintenance, PAC H pumps take
advantage of digital technology. They are equipped with QR codes that mean essential information
about parts and spares is just a scan away. Users can also take advantage of the fleet link secured and
remote monitoring feature that means they are always in control of pumping operations.

Conclusion
Atlas Copco has addressed traditional issues of inaccessible hydraulics and the need to disassemble
pumps to perform simple tasks like replacement of consumables. In combination, these features can
improve MTTR by up to 30%. However, improvements to pump design can only achieve so much in the
drive to improve efficiency and optimize uptime. Availability of spares and adequate training are also
essential and these support services are provided through Atlas Copco’s global network of customer
centers.

SKF introduces hydraulic barrel pump

4 May 2021
FacebookTwitterLinkedIn மேலும்

The BPH30 is designed for large automatic lubrication

systems and filling processes.
Swedish pump manufacturer SKF has launched its BPH30 hydraulic barrel pump for large
automatic lubrication systems used in demanding applications such as heavy machinery used in
the construction and mining industries.
The BPH30 pump is available with or without sensors and can be configured to individual needs. It is
designed for large automatic lubrication systems such as single-line, progressive or dual-line, as well as
filling processes.

The BPH30 is constructed from heavy-duty materials, making it very robust. It also has a compact
design, allowing it to be mounted in tight spaces, an operating temperature range from -40°C to +80°C
and accepts greases up to NLGI 2. The pump has a single outlet, which can be positioned on the left,
right or front of the device.

A special three-seal design helps to prevent leakage of both hydraulic oil and lubrication grease. This
maintains safe and reliable operations, while minimising the risk of contamination. A leakage indicator
provides clear visual confirmation that the sealing system is working.

Built-in sensors monitor oil pressure, temperature and piston movement, which helps to avoid sudden
machine failure.