By |January 24th, 2019|Uncategorized|0 Comments

Major Factors to Consider in Designing and Installing a Chemical Injection Skid System

6. Assembly, Reliability and Testing

By definition, any system is an assembly of many individual components, parts and sub-assemblies. Many of these are manufactured by separate companies. When the system does not work properly it results in each manufacturer suspecting the issue to be with the other component manufacturer. As a result, this experience could become very frustrating quickly. Proper care and evaluation at the time of selection of these components are essential. Understanding of compatibility between components requires mechanical, hydraulic, electrical and chemical analysis to ensure these work well together and produce the end result desired by the customer. This is where a good systems integrator comes in with the expertise and experience to make it all come together and perform as per expectations.

One of the important considerations during the assembly is that it should be designed not only to perform onsite but also be able to withstand the movements and impacts during transportation if the system is assembled offsite. Adequate provisions need to be allowed to lift and place it in a truck, unload it from there and place it precisely on the intended site. While many pipes and fittings can be adequately supported for onsite operation, they will not be able to survive the transportation and handling resulting in leaks. Hence extra support should be installed for pipes and any other heavy component. The pipes also need to have easy to assemble unions at the ends so the suction and discharge piping can be installed correctly and quickly. A flexible coupling or tubing may be required in difficult and demanding situations. Do not have pipes or fittings carrying chemicals directly above important and sensitive components which will be vulnerable to a drip of […]

By |January 24th, 2019|Uncategorized|0 Comments

Major Factors to Consider in Designing and Installing a Chemical Injection Skid System

5. List of major components and procurement planning

While the chemical pump is the central unit of this system, it cannot work effectively without correct accessories and components that make a wholesome functioning system. The basic requirement for a metering pump hook up is to have a calibration column and strainer before the pump and pressure gauge with isolator, pulsation dampener, back pressure valve, pressure relief valve and flow meter on the discharge as shown in the graphic below. Most people think they do not need some or many of these accessories. However they are important in their own rights. Calibration column is more than just a flow measuring device, it also shows the effectiveness or lack thereof of the check valves on the pump. If the meniscus on the calibration column drops steadily it shows good valves, if it bounces around it indicates the check valves are leaking. A strainer prevents debris from getting caught into the check valves which causes leakage when it is closed. The pressure gauge is the stethoscope for the system which shows the pressure and how it fluctuates with each stroke. The back pressure valve ensures that there is enough back pressure on the check valve to close regardless of the discharge conditions. Pulsation dampener will reduce the pressure fluctuations giving a more steady read out from the flowmeter.

Depending upon the size and scope the chemical tank should be taken into account. If the tank is just a day tank and hence small it is often mounted on the skid itself. If not t hen it is located close by and the pump located below the level of the chemical at the lowest level to allow for flooded suction for […]

By |November 8th, 2018|Uncategorized|0 Comments

Expedited Production with 2-3 Day Delivery Coast to Coast from AquFlow

AquFlow over the years has built a solid reputation for industry leading quick production and deliveries. We have now formalized the process of an Expedited production, testing and deliveries for those unplanned pump emergencies. For most standard pump models we can expedite the whole process from order to delivery in less than a week. Call us and ask for Expedited Pump Delivery (EPD) if you need a pump in a hurry.

We have partnered with a couple of major LTL trucking companies that can deliver any pump, skid or a complete system to any of our customers coast to coast in 2-3 days. This is the standard service without paying any Express or Expedited charges. So when you need a large pump, skid or a complete system to be delivered almost anywhere in the 48 states, please ask us for the 2-3 days LTL service without any extra charge. This is just another way we try to serve our customer better and faster.

By |October 12th, 2018|Uncategorized|0 Comments

Major Factors to Consider in Designing and Installing a Chemical Injection Skid System

4. Control Systems For The Skid

This is where we decide about the controls for the delivery of the chemical (and hence the pump) and sensors to verify if the system is doing what it is expected to do.

The first thing we take into consideration here is the power that is available. That will determine the selection of the motor, sensor and controls. Usually that power is single or three phase AC voltage. Although in remote areas there could be the need for DC power especially if the source is a generator or solar.

The flow of the chemical can be regulated by using a VFD on the motor to regulate the speed or by an automatic stroke adjustment system (like AquFlow’s ECCA) which will increase or decrease the effective stroke length. Many engineers prefer a combination of the two controls calling it a Dual Axis control. Both these controls can be driven by a 4-20 mA signal from an external system such as SCADA which takes into consideration several other inputs such as flow or quantity of the water to be treated, contamination level etc.

Once the flow of the chemical is controlled it is often recommended to measure the output of the chemical in the pipe line by suing a flow measurement device. This device again communicates back to a central system like SCADA which takes this input and fine tunes the pump flow capacity by one or both of the above methods.

If an external control system like SCADA is not available, AquFlow offers a self contained control unit called IVAX which stands for Intelligent Verification and Control System. This has the ability to offer a complete feedback loop to send control signal, verify the actual […]

By |October 12th, 2018|Uncategorized|0 Comments

Major Factors to Consider in Designing and Installing a Chemical Injection Skid System

3. Chemical, Performance and Specifications

This is at the heart of any chemical injection system. Dispensing and handling chemicals is the Raison D’etre (the main purpose) for the system. Choice of material of construction for the wetted parts and its corrosion resistance is not just a reliability issue but also a serious safety concern. The rate at which the chemical needs to be injected directly impacts the  effectiveness of the process. The pressure at which the chemical needs to be delivered would dictate the strength of the pipes and power for the driver / motor for the pump.

Here we delve deep into what chemical we are pumping, where it is coming from (source tank) and where it is going (injection point) along with the precise flow rate and the pressure it needs to overcome. Metering pumps do not perform well if the suction line is too long or too narrow. Hence the location of the supply tank in relation to the pump skid needs to be within a reasonable distance. The pipe diameter for the pump needs to be large enough so it does not offer enough restriction to starve the pump in its fill cycle. Another concern is the relation of the location of the pump to the tank chemical level on a vertical axis. If the pump has to lift the chemical from a level that is far below the pump suction port, the pump needs to be chosen with enhanced suction capabilities.

Additionally the corrosion resistance to the chemical for the pump, piping/fittings and any other component that comes in contact with the chemical needs to be carefully examined before material of construction is chosen. Often times the main material is chosen correctly to […]

By |September 13th, 2018|Uncategorized|0 Comments

Major Factors to Consider in Designing and Installing a Chemical Injection Skid System

Scope and Compliance: Define clearly the purpose and functions of this skid system. Here you will define what chemical it is pumping, what would be the flow and pressure of that chemical. What is the function of the chemical in the overall process? How critical it is and if it requires redundancy and what is the duty cycle. Also briefly describe the environment where the system is located and where it will be injecting. Depending upon the application, industry and environment there will be a list of compliance requirements. Make a complete list of pump, environmental, structural and locational compliances.

Location / Structural & Power: Both the location of the facility and the location of the system within the facility are major factors that need to be surveyed. The structure on which the system will be mounted and structural requirements of the skid itself needs to be defined based upon the location and its vulnerabilities. The availability and feasibility of power which in most cases would be electric and in some cases would be solar or pneumatic would determine the motive system driving the injection pump.

Chemical and Performance Specifications: Choice of material of construction for the wetted parts and its corrosion resistance is not just a reliability issue but also a serious safety concern. The rate at which the chemical needs to be injected directly impacts the  effectiveness of the process. The pressure at which the chemical needs to be delivered would dictate the strength of the pipes and power for the driver / motor for the pump.

Control System: This is the brains of the system. The control system turns the pumps or valves on and off depending upon the verification of the actual flow delivery. […]

By |August 2nd, 2018|Uncategorized|0 Comments

Know Your Chlorine

Chlorine is one of the most commonly used disinfectants for water disinfection. Chlorine can be applied for the deactivation of most microorganisms and it is relatively cheap. Chlorine (Cl2) is one of the most reactive elements; it easily binds to other elements. In the periodic table Chlorine can be found among the halogens.

Watery chlorine should be protected from sunlight. Chlorine is broken down under the influence of sunlight. UV radiation in sunlight provides energy which aids the break-down of underchloric acid (HOCl) molecules. First, the Water molecule (H2O) is broken down, causing electrons to be released which reduce the chlorine atom of underchloric acid to chloride (Cl-). During this reaction an oxygen atom is released, which will be converted into an oxygen molecule: 2HOCl -> 2H+ + 2Cl- + O2

Chlorine is produced from chlorine bonds by means of electrolytic or chemical oxidation. This is often attained by electrolysis of seawater or rock salt. The salts are dissolved in water, forming brine. Brine can conduct a powerful direct current in an electrolytic cell. Because of this current chlorine ions (which originate from salt dissolving in water) are transformed to chlorine atoms. Salt and water are divided up in sodium hydroxide (NaOH) and hydrogen gas (H2) on the cathode and chlorine gas on the anode. These cathode and anode products should be separated, because hydrogen gas reacts with chlorine gas very aggressively. Chlorine-based bleach is applied as a disinfectant on a large scale. The substances are also used to bleach paper. Bleaching occurs as a result of chlorine or hypochlorite oxidation.

About 65% of industrialized chlorine is used to produce organic chemicals, such as plastics. About 20% […]

By |March 14th, 2018|Uncategorized|0 Comments

Leak Detection Systems for Hydraulic Diaphragm Metering Pumps

Aquflow hydraulically-actuated diaphragm metering pumps are by design both rugged and leakproof. However, in some difficult and/or critical chemical feeding applications, it is often desirable to add diaphragm leak detection – whether to protect the pump from hostile chemicals or to protect the process from possible contamination by hydraulic fluid.

For these applications, AquFlow has developed two highly reliable diaphragm leak detection systems. Your NPA sales representative can help you determine which system is best suited for your particular needs.

Series 3000 Pump w/ PVDF Liquid End and Conductivity Probe

Conductivity-Type Leak Detection

The conductivity-type leak detection system can be furnished on either tubular/disc diaphragm or double disc type diaphragm liquid ends. The system consists of a conductivity probe mounted in the pump intermediate chamber between the diaphragms. This intermediate chamber is filled with process compatible non-conductive fluid.

In the event of a diaphragm failure, process fluid leaking into the intermediate chamber results in a change of conductivity. This change in conductivity of the intermediate fluid increases probe current through the sensing circuit of the solid state control module. When the probe current exceeds the setpoint current, the control module energizes a relay output.

Series 1000 w/ Vacuum-Leak Detection

Vacuum-Type Leak Detection

The vacuum-type leak detection system is a highly reliable means of sensing diaphragm failure, and is frequently used when the process fluid will not allow a conductivity-type system. The vacuum-type system consists of two PTFE diaphragms held together under vacuum and separated by a thin, metallic intermediate ring. In this system, diaphragm failure is detected by sensing a change in vacuum pressure between the two diaphragms.

The complete leak detection system includes a vacuum gauge, tubing, purge valve, vacuum accumulator, and a factory preset vacuum switch. The U.L. listed SPDT vacuum switch […]

By |May 28th, 2015|Products, Uncategorized|1 Comment

Top 5 Causes for AODD Pump Failure

1.       Air Valve Stalling, Clogging or Leaking: Stalling of the air valve often has to do with the design of the airways inside the valve. If the design in less than optimal it will stall under certain conditions. Same can be said about leakage of air where the air mostly blows through the valve instead of being redirected to push the diaphragm. Clogging on the other hand could be due to the quality of the air you are using. Make sure you use filtered air to run the pump.

2.      Diaphragm Rupture: The diaphragm in an AODD pump is always subject to mechanical stress and over time it causes stress cracks and failure. Material of the diaphragm combined with the method of manufacturing plays an important role in the longevity of diaphragms. Another important factor is the pressure. The higher the pressure the higher is the stress on the diaphragm. Lastly the number of strokes is the ultimate measure for the life of the diaphragm. Pumps that run faster will likely fail more quickly.

3.      Check Valve Failure: Usually AODD pumps use ball style check valves. These check valves are likely to fail due to something getting in between the ball and the seat preventing a good firm leak-proof closing of the valve. Use of a strainer will reduce this possibility. Additionally flushing the pump when you suspect something is stuck often clears the check valves of debris. Wear of the ball and seat also causes leak paths. This wear could be due to abrasive particles in the liquid or just a matter of poor material choice for balls or seats.

4.      Muffler Icing or Clogging: The main reason for the muffler icing is the […]

By |February 12th, 2015|Uncategorized|0 Comments