Air-operated diaphragm pumps are versatile and efficient solutions for fluid transfer in various industrial applications. This guide will provide essential information on their benefits, maintenance strategies, and performance comparisons with other pump types.
Versatility Across Applications
Air-operated diaphragm pumps can handle a wide range of fluids, including corrosive chemicals, slurries, and viscous materials. Their ability to operate dry without damage makes them suitable for diverse industries such as mining, chemical processing, and wastewater treatment.
Self-Priming Capabilities
These pumps can self-prime to depths of up to 8 meters (26 feet), enabling effective operation in challenging environments. This feature reduces installation complexity and enhances operational efficiency.
Low Maintenance Requirements
The simple design of air-operated diaphragm pumps minimizes component wear, reducing maintenance frequency. Regular inspection ensures optimal performance without extensive downtime.
Energy Efficiency. While AODD pumps offer unique advantages, including operation in hazardous environments, the ability to run dry, and excellent handling of viscous/abrasive fluids, electric-driven pumps typically provide superior energy efficiency. For applications where compressed air is already available or where electrical power is impractical, AODD pumps remain an excellent choice for their reliability and versatility.”
Safety Features
Air Diaphragm pumps are the safest type of pump technology for use in industries today. SELF PRIMING. The ability to self-prime means that one does not need to handle acids, alkaline solutions, or other toxic chemicals to prime the pump. The AODD Pump will not generate pressure above the system’s air pressure, which means the pump will stop once the fluid pressure equals the input air pressure—no damage to pipework or seals, a significant safety feature when handling toxic fluids. Seal-less. Without a rotating shaft, the AODD pump has no mechanical seal. The diaphragm acts both as the motive force behind fluid transfer and as a static, hermetic seal. This seal-less system is ideal for transferring toxic acids, petrochemicals, and fuels.
Regular Inspections
Schedule routine inspections every three months to assess the condition of key components such as diaphragms, valves, and seals. Look for signs of wear or leaks that could impact performance.
Diaphragm Replacement
Replace diaphragms every 1-3 years based on usage intensity and fluid type. Operating under harsh conditions may necessitate more frequent replacements to ensure reliability.
Lubrication Checks
Many AODD pumps do not require lubrication for regular operation. It is, however, crucial to ensure that the compressed air is free of carryover oil from the compressor. “Wash out” of the lubrication these pumps have on assembly can be caused by high volumes of water in the air. It is essential to ensure that a correctly sized air filter with an autodrain is attached to the airline feeding the pump’s air motor. While many users do not install Air Filter/ Regulators on each pump, the best practice is to do so. Without proper air dewatering, one needs to include a complete lubrication service for the air valve/motor every 30 days. With NQOBA pumps, this is very easily accomplished as the air valve/motor is quickly accessed without stripping the pump. Simply opening the cover allows one to repair/lubricate the entire air assembly and inspect the diaphragm for viability.
Cleaning Procedures
Implement cleaning protocols after handling abrasive or corrosive materials to prevent buildup that could impede functionality or damage internal components.
Monitoring Performance Metrics
Track flow rates and pressure readings regularly to detect any deviations from expected performance levels early on.
Versus Centrifugal Pumps
Unlike centrifugal pumps that rely on rotating impellers to move fluid, air-operated diaphragm pumps use a flexible diaphragm mechanism, allowing them to handle solids more effectively and avoid clogging, which is common in centrifugal designs. AODD Pumps do not have rotary mechanical seals, the diaphragm seals the fluid from atmosphere and the drive shaft, this means there is no leakage compared to mechanical seals which will fail due to dry operation or abrasive solid handling.
Versus Positive Displacement Pumps
While both types offer accurate flow control, air-operated diaphragm pumps excel in applications requiring variable flow rates because their adjustable pulse settings enable real-time modifications based on demand. Furthermore, AODD Pumps offer greater safety than other types of positive displacement pumps. A gear/piston or progressive cavity pump must include a pressure relief system. Should a discharge valve be closed, these types of positive displacement pumps will continue to generate pressure until something fails, a pipe bursts, a seal ruptures, etc. The AODD pump will stall as the pressure on the fluid side equals the pressure on the air side. This safety feature in the air pump is one of the main reasons AODD Pumps are so extensively used.
Efficiency Ratings Comparison
When it comes to the efficiency of air-operated double diaphragm pumps compared to other pump technologies, the units’ efficiency is measured by the uptime they provide, not by power input. An AODD Pump relies on a compressor to generate the drive air volume and pressure. Correct sizing of the pump to the compressor is vital for the best power-to-pump performance ratio. (LINK TO EFFICIENCY CALCULATOR) It is best to contact INPDI technical support (Tech@inpdi.online or call +27 826519841) for pump selection to ensure the pump is correctly matched to the compressor.
Cost Considerations
Initial costs may vary by pump type; however, consider long-term operating costs when evaluating overall value propositions—air-operated diaphragm pumps typically incur lower maintenance costs than gear or screw pumps, subject to the operating conditions and operator.
Industries such as mining, food processing, pharmaceuticals, chemical manufacturing, and wastewater management frequently use air-operated diaphragm pumps for their robustness and adaptability in handling a wide range of fluids safely. Furthermore, these industries rely extensively on unskilled or poorly skilled labour to operate and maintain the pumps. AODD Pumps enable far lower breakages and failures than rotating electrical products.
The variety of materials of construction one can select for chemical handling is almost unprecedented compared to other technologies. Selecting from Polypropylene, PVDF, Stainless Steel, Cast Iron, Aluminium, and Steel provides the most versatile options compared to most other pump systems. Elastomer options in Teflon, Santoprene, Viton, Hytrel, EPDM, and Buna provide exceptional options for handling acids, alkalines, and petrochemicals. The correct pump selection for the required duty will determine the installation’s effective efficiency. The fluid flow rate and discharge head must be correctly determined to select the right pump model. NQOBA experienced pump technical representatives are trained to assist you with this selection. It is worth requesting help, as this selection directly influences efficiency. An incorrect selection may result in the pump using far more air volume and requiring much higher pressure to perform at the duty point.
Regular inspections of the diaphragms, along with lubrication checks, are crucial for maintaining peak performance throughout the pump’s lifespan.
They offer advantages in versatility and low maintenance compared with centrifugal or positive-displacement alternatives, while ensuring safe, reliable operation across a wide range of applications.
To explore further details on selecting reliable pumping solutions tailored to your operational needs, contact our technical team tech@inpdi.online or call 0826519841