The proof is in the pump
PUMPS
Air-operated double-diaphragm (AODD) pumps have played a profound role in the modern global manufacturing and fluid-handling operations of many companies for more than 50 years. The original pump concept has changed little over the decades and works through its sheer simplicity of operation and construction. With operating efficiency and cost reductions being a major focus of businesses today, AODD pump manufacturers have introduced new technologies in air distribution systems (ADS) to increase pump efficiency and meet these demands. The new ADS technologies utilized range from electronic controls to mechanical innovations. However, the resulting savings in compressed air usage and increase in pump efficiency varies considerably by the system. This white paper will present the results of head-to-head comparisons between the top AODD pumps and the final data acquired during those tests. The results will help illustrate the impact differing ADS technologies have on air consumption, energy use and overall flow rate. The Challenge In AODD pump operations, energy use is directly related to the rate of consumption of air used to drive each stroke of the pump during the pumping cycle. With increasingly high energy costs, facility operators understand that the initial purchase and installation of a new pumping system is but a small part of the total cost of ownership and operation during the pump’s life cycle. Routine costs of energy and maintenance remain the primary cost drivers in the total cost of ownership.
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Pipes, Pumps and Valves Africa - Jul/Aug 2021
Much like cars, pumps can be rated according to efficiency. The goal is to utilize the least amount of air to pump the greatest amount of product. The ultimate objective is to reduce the rate of air consumption about the product flow rate while also minimizing the overall amount of air that is not producing product yield (wasted energy) during the pumping cycle. If attained, this combination will directly impact an operation's bottom line — the profitability being determined by something as simple as the volume of air being consumed and the energy required to compress it. In addition to wasted energy, air overfilling stretches the diaphragm unnecessarily. This stretching produces excessive diaphragm wear and tear resulting in more frequent replacement and downtime, while also increasing operating costs. Second, this electronic ADS technology requires a "learning period" of 30 to 40 seconds where it monitors the operation of the pump before it can estimate when to cut off the air supply before the end of the stroke. This can result in erratic and sometimes wasteful flow rates during this learning period. During the period from the end of each stroke to the completed shift of the valve, the air is allowed to "overfill" the air chamber without any corresponding displacement of fluid. This volume of compressed air is entirely wasted.
