In any manufacturing plant, downtime is one thing that shouldn’t be tolerated. A stop or delay in production means a loss of revenue.
To reduce or avoid this, plant personnel must ensure the machines are working and running smoothly. Any maintenance and upgrade required by the machinery should be performed before it’s too late.
A common piece of equipment that plays a significant role in a plant is a diaphragm pump. A working pump should always maintain a low downtime and increase efficiency to the maximum. It is also advisable to get replacements directly from manufacturers like KNF to avoid getting counterfeit parts and invalidating your warranty.
Therefore, to increase the reliability, improve the overall performance, and realize the benefits of using the pump, consider the following tips:
1 Choose The Right Position Of The Pump
While fixing a pump in a system, its location is critical because it will determine how long it will perform effectively and how easy it will be to repair or replace it. While you can use the diaphragm pump for various reasons (e.g., as a suction pump), positioning it appropriately will help reduce the stress imposed on it.
2 Choose The Right Pump Materials
Diaphragm pumps are made of carefully selected materials to improve their reliability and performance. In most cases, these pumps come into contact with fluids. The fluid’s characteristics will determine the kind of pump ideal for the system. Besides considering the internal components, it’s crucial to understand the external environment in which the pump operates.
Does its surrounding contain fumes? The diaphragm pump should therefore be compatible with that. If exposed to UV light from the sun, plastic pumps may not be recommended. In any case, you’ll have to seek professional advice to have the right pump for the plant.
3 Check The Quality Of Compressed Air
How do you make a pump last longer? Perhaps, air quality is a factor when it comes to the pump’s durability. Compressed air is what runs the pump. Although these pumps are designed to work even under poor air quality, the use of clean air is better for its performance.
Wear and tear is a major problem in a diaphragm pump. To avoid this, the dynamic valve and main shaft should run on clean and dry air.
4 Install A Filter
For the pump to work efficiently, its air pressure should be controlled. Installing a filter or regulator will allow you to manage the pump’s air pressure.
Without a filter, the air pressure will be more than what is needed by the pump. Meanwhile, exposing the pump to too much air pressure could cause unnecessary pump cycles, reduce the pump’s life span, and affect its overall performance.
5 Track The Diaphragm Pump Performance
Unfortunately, you’ll never know when the pump is about to break down. You can only notice a reduction in its flow and increased downtime. Until a repair is made, expect a suboptimal performance.
Every plant is unique and has applications that vary. Tracking the pump performance might be ambiguous because there is no standard maintenance schedule. Thus, understanding your pump is essential to know what’s best for it. Research other plants with similar applications to get an insight into when its pump usually needs service.
6 Control Pulsations By Installing Accessories
Installing diaphragm pump accessories eliminates undesirable pulsation. By doing this, you optimize the pump, increase its life span, and experience less system vibration that would have otherwise caused loose connections. Some accessories, such as flexible fluid connections, help reduce pipe stress that might cause leakage or otherwise damage fluid castings.
Installing liquid-filled pressure gauges on the inlet and outlet will help in the overall performance of the pump. All the information about blockage, restrictions, or pressure imbalance will be windowed through this gauge.
Lastly, having an inlet stabilizer on the suction side of the pump minimizes the pressure spikes experienced during suction strokes.
7 Do Complete Maintenance Of The Pump
The diaphragm pump is made up of several components. Changing all the features will be ideal if a part of the component fails. For example, if you are replacing a seal, you might as well change all the seals in the pump. This might be expensive but will save you from frequent repairs in the future.
A worn-out part working with a new piece may result in the tearing down of a pump. This would lead to incompatibility and reduced efficiency of the pump.
A diaphragm pump’s performance will be determined by how frequently you do maintenance checks. Most plant operators lack enough knowledge about the pumps they are operating. Therefore, it would be best to check on your diaphragm pumps regularly and ensure that they get the repair they need.