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Dosing Liquids
Conveying Gases
Control Solids
Brief Introduction to Dosing Technology
Lutz-Jesco GmbH
Dipl.-Ing. Günther Bolte
Table of Contents
Preface
There is almost no industrial branch or plant which does not apply the “dosing“ function in some way
or other. Dosing technology is used for the production of chemicals and products as well as for their
economical and ecologically beneficial application in manufacturing industries. A significant number of
users of dosing technology are waterworks and sewage treatment plants as well as swiiming pools for
conditioning the pool water.
The spreading of dosing technology to increase the quality and economic efficiency of processes
requires more information and training on “dosing technology“ so that unsatisfactory results in dealing
with it can be avoided. The following “brief introduction to dosing technology“ aims at explaining its
basic principles and those of the media to be dosed in a deliberately simple way. The purpose is to
avoid errors in planning dosing systems and to optimize system not operating satisfactorily. In
addition, a number of impulses might well be given to control chemical dosing automatically where it
was done manually before. There is no doubt that a mechanically or better automatically controlled
dosing system improves the result and reduces or avoids the recurring mistakes and weaknesses of
the human factor.
The following article starts with a description of some chemical properties and then continues to
explain different principles of dosing. Special attention is paid to the use and right installation of
fittings/accessories which only enable dosing in many cases but definitely improve the result.
4
0.1 Properties of media
0.1.1 Solid, liquid and gaseous substances
All pure, elemental substances can occur in atmospheric pressure, if it is explosive or
gaseous, liquid or solid condition. The state of poisonous or becomes aggressive in
the substance depends on pressure and combination with moisture.
temperature. A familiar example is water at The answers to these questions give an idea
atmospheric pressure: below 0°C water is of what will happen in the case of leakage.
frozen solid, between 0°C and 100°C it is liquid For the selection of fittings or dimensioning of
and above 100°C it converts into steam. piping for gases, calculation methods and
Liquids which are made up of mixtures of diagrams must be applied which take the gas
different chemicals have no precise melting or laws into account (not to be mixed up the
boiling point because the individual diagrams prepared for liquids).
components solidify or volatilize at different Special dosing equipment has been developed
temperatures. This fact is e.g. made use of to for the last decades particularly for chlorine
distil the different components (fuel oil, petrol, gas which is used extensively for treating of
etc.) from crude oil. potable water, swimming pool water and also
Knowing the boiling behaviour of a liquid is waste water. It has been improved to such an
also important since it determines the suction extent that it is now included in the German
lift of the liquid achievable by pumps. Also Standard Sheets (e.g. DIN 19606 or 19643).
because then the consequences of leakage Solid matters are all those substances
can be evaluated more exactly. The question occurring in solid condition within the relevant
of whether the liquid will remain in liquid temperature range. Depending on the
condition or evaporate spontaneously in the formation or production process, the particle
case of leakage may be important when diameter may differ from dust to several
selecting the type of dosing pump (e.g decision centimeters. The choice of the suitable dosing
for a leakproof version). unit does not only depend on the grain size but
For application engineers it is important to also on the shape of the grain, i.e.: the grain
know whether the liquid is heavier or lighter geometry.
than water, if it can be mixed easily or only Dosing of solid matters implies that the
partially with water, if it tends to precipitates, substances are in a relatively homogeneous
whether it is aggressive, abrasive or dischargeable state concerning their particle
combustible, and its viscosity. Most liquids can size in relation to the total quantity of the bulk
be regarded as non-compressible with material. Therefore it is a prerequisite that for
negligible influence up to 100 bar. most process the dry material is supplied
In contrast to liquids, gases occupy any either as powder or as granulates with grain
available space. Important gas values gases sizes of up 5 mm. But also in the case it is a
are those for temperature, density and question of scale. Broken stones with
pressure, all dependent of each other. For diameters of 50 mm, for example, are still
process technology it is e.g. significant relatively easy to dose if the magnitude of track
whether the gas is under vacuum or under installations or coal feeding systems in power
pressure, if it is heavier or lighter than air at plants are taken into consideration.
0.1.2 Viscosity
Liquids and gases are more or less flowable. Viscosity has different modes. Some liquids
This property is specified by their viscosity. have a certain viscosity at a given temperature
The lower the flowability the higher the which does not change at varying velocities of
viscosity. In the case of gases viscosity is of flow. Most liquids, however, behave differently.
minor importance as far as dosing units and There are some which show a high viscosity in
fittings are concerned. It is, however, taken idle position and become relatively fluid when
into account for the calibration of measuring flowing (as e.g. non-dripping varnish which
glasses (float element flow meter). Viscosity is clings to the brush as it is applied to a vertical
very important for liquids because the wall and then becomes fluid through the faster
readiness of the liquid to flow strongly effects movement of the brush. After painting the
the dosing capacity of the pump. This is due to varnish immediately becomes highly viscous
the fact that the nominal output of dosing again and does not drip). Other liquids behave
pumps is determined with water at 20°C. With the other way round. They are fluid in idle
increasing viscosity, i.e.: with lower flowability positon and become more viscous at higher
of the liquid, it becomes more and more velocities (this can be a problem when using
difficult for the pump to force the set quantity e.g. agitators).
through the dosing and piping system.
5
Effect of
viscosity
Auswirkung
der Viskosität
3
2
α Viscosity
=Viskosität
Strömungsgeschwindigkeit
Velocity of flow
11 Intrinsically
strukturviskosviscous (viscosity
(Viskosität nimmt mitdecreases
wachsender with increasing velocity
Geschwindigkeit ab)
22 Theoretical liquid (viscosity remains constant)
theoretische Flüssigkeit (Viskosität bleibt konstant)
33 Dilatant liquid (viscosity
dilatante Flüssigkeit grows
(Viskosität withmitincreasing
nimmt wachsendervelocity)
Geschwindigkeit zu)
Viscosities
Medium 20 °C mPa*s
Air 0.02
Water 1.0
Acetone 0.3
Organic solvent 0.5 ... 3
Sulphuric acid 100 % 27
Cooking oil 100
Motor oil SAE 20 200
Machine oil 20 ... 500
Warm fuel oil 7000
Honey 2000 ... 50000
6
0.1.4 Sedimentation, flotation sedimentation, the rising of particles to the
Larger particles in the range of 0.001 – 1 mm surface is called flotation. The latter can be
carried in liquids tend to float or settle, accelerated by injecting air. Both occurrences
according to their specific gravity in are used to separate undesired or desired
comparison to the carrying liquid. The slower matter from liquids. Removing the floated
the velocity of flow, the faster the particles are particles over the tank edge is also called
able to either rise to the surface or sink to the decantation.
bottom. The settling of particles is called
High Geschwindigkeit
hohe velocities keep hält
the
particles
Partikel in in suspension
Schwebe
Low velocities allows
geringe Geschwindigkeit
particles to settle gibt Partikeln
Zeit abzusinken
Liquid withmit
Flüssigkeit small number
wenigen of particles
Partikeln
0.1.5 Abrasion
Particles suspended in the liquid which – as depends particularly on the hardness and the
mentioned before – can sediment or float due surface structure of the small particles. All
to their size have a more or less abrasive suspensions are abrasive when in motion.
effect when in motion. The degree of abrasion
Due to inertia the particles
trägheitsbedingt
continue tobewegenflow sich die Teilchen
straight on and
geradeaus weiter und erodieren den Rohrbogen
erode the pipe bend
0.1.6 Aggressiveness
Aggressiveness of a liquid is its characteristic most important factors to be considered when
to corrode other materials. Gases or solid selecting materials for fittings and piping. A
matters can be highly aggressive after being measure of aggressiveness is e.g. the pH
dissolved in water or in contact with air value of the liquid. Neutral liquids have values
humidity (e.g. the “solid” salt or the “gas” around "7" whereas lower values indicate
chlorine dissolved in water). The increasing acidity and values up to 14 indicate
aggressiveness of chemicals is one of the increasing alkalinity.
pH value
pH-Wert
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Salzsäure acid
reines Wasser
Seifenlösung
Natronlauge
Caustic soda
Meerwasser
Zitronensaft
Soapy water
Lemon juice
Hydrochloric
Pure water
Blutwater
Milch
Blood
Bier
Beer
Sea
Milk
7
0.1.7 Release of gas
There are chemicals which either contain systems, since many fittings can only handle
gases in solution or which decompose in the pure, gas-free liquids. Especially the dosing
course of time and thus release gas from the pumps constructed for liquids have larger or
liquid. This process referred to as degassing smaller dead spaces which have the effect that
must be considered from different point of gas entering the head cannot be compressed
views. to operating pressure. Thus it cannot leave the
One important aspect is the danger to head and dosing fails. To solve this problem,
environment, another point is that degassing various measures have to be taken (for further
affects the function of pumps and piping details, refer to the text below).
Angle of repose
8
0.1.9 Burning and explosion behaviour
It is of greatest importance in chemical containing reaction partners which cause
engineering to know the burning and explosion ignition or explosion due to high temperatures
behaviour of the media to be handled. This or shocks. These materials are particularly
topic is too essential to be discussed here dangerous because they can ignite even in
shortly. Therefore the relevant literature as well closed tanks under exclusion of air. In general
as the rules and regulations for prevention of the chemico-physical reaction is stronger the
accidents have to be studied carefully. larger the surface of the reaction partners. It
Inflammable materials are subdivided and makes sense that the surface of a certain
clustered according to their burning and mass increases with smaller particles. This
explosion danger potential. It is particularly also explains that there is the danger of dust
important to consider the explosion explosions. Besides, materials are also
classification when using electrical machines distinguished according to their ignition
because of possible sparking. It must be performance and their strength of reaction
checked whether the gases, liquids and solids after having ignited once. There are
to be dosed might form inflammable mixtures substances which ignite easily but do not
under certain operating conditions. In most release a large amount of energy, and there
cases oxygen which is always present in the are others which are hard to ignite but which
atmosphere will be the reaction partner. There cause a violent explosion.
are, however, also chemicals already
0.1.10 Density
The density of a substance indicates how temperature is the same). A liquid on the other
many kilograms are contained in a cubic meter hand will only occupy half of the double
(kg/m³). It is expressed in relation to the volume, and the density will remain constant.
density of water which is 1.000 kg/m³. The specific weight of the particles of a solid is
While the density of liquids is relatively virtually constant. But since the mass of bulk
constant and alters only slightly with pressure material in a given space depends on how
and temperature, the density of gases is close together the particles are, the density is
greatly dependent on pressure and variable in practice and must be determined by
temperature. The same mass of gas has in experiment (powder density or tap density).
double the space only half the density, Firmly tapped bulk material will have a higher
because gas is able to expand to twice the density than loosely poured powder.
volume at half the pressure (provided that the
9
Bulk material
Schüttgut
The
Die density
Dichte of bulk material
von Schüttgut depends
hängt ab vom on the „tapping“ condition
"Rüttel"-Zustand
V V
10kg lose
10 kg geschüttet
loosely poured 10kg fest
10 kg geschüttet
firmly tapped
V=1dm3
V=1dm3 wiegt 0,8kg0.8 kg
weighs V=1dm3
V=1dm3wiegt 1,1kg1.1 kg
weighs
Flüssigkeit
Liquids
Die
TheDichte der Flüssigkeit
density of liquidsbleibt unabhängig vom
is independent Raumangebot
of the volume
V V
V=1dm3wiegt
V=1dm3 weighs
1kg 1 kg V=1dm3
V=1dm3 weighs
wiegt 1kg 1 kg
Gases
Gase
The
Die density
Dichte of gashängt
von Gasen depends
ab vonon pressure
Druck and temperature
und Temperatur
V V
10
0.2 Methods of dosing
0.2.1 Continuous and quasi-continuous dosing
Processes which deal with continuous several minutes to hours, fluctuations within a
manufacturing or treatment of products mostly second are not a problem. It is just a question
require an equally constant addition of of the actual dosing period whether a dosage
chemicals such as acids, lyes, dyes, aromatic process can still be considered as continuous
substances, flocculants, etc. Strictly speaking or discontinuous. If the total dosing period is
the term “constant” refers to a continuous, only a few seconds, fluctuations within a
uniform addition of the aforementioned second are not admissible. But if the
chemicals (a permanently running water tap fluctuations are relatively short in comparison
would be the best comparison). However, as to the total dosing period so that the result
will be explained later, for certain reasons corresponds to a continuous dosage process,
dosing units have proved to be suitable which this is referred to as “quasi-continuous” dosing.
show considerable fluctuations in the dosing Thus quasi-continuous dosing can also be
rate over a period of time of one second but regarded as continuous dosing if it is ensured
which dose exactly the same amount on a that, at any given moment of verification, the
statistical average of longer periods due to the rate dosed in the past corresponds to the
uniformity of these fluctuations. For those actual requirements.
processes which have production times of
2
1
11Sekunde
second 11 Sekunde
second 11 Sekunde
second
11
water meters), the latter can be used to are dosing units to be used universally not only
activate a dosing unit for a determined period in potable water treatment applications but
of time. The running period must be completed also in general process industries.
before the next control pulse is received. This With proportional dosing the result is only
type of proportional dosing also allows precise constant if all characteristics of the medium to
dosing on a statistical average of longer be treated, the dosing chemical and the
periods. During the time of dosing, the quantity process data such as pressures,
added is, however, larger than required with temperatures, viscosity, etc., which were taken
regard to the water flow, because, after into account for the system design, remain
completion of the running period, no dosing constant as well. Thus the properties of the
takes place for a certain interval. Careful water to be treated, for example, must not vary
mixing ensures in the piping system that the as otherwise the defined dosing quantity is
water is treated correctly. It is, however, the either too high or too low. If considerable
final decision of the process engineer whether changes in the water properties are likely,
this type of dosing is admissible. Only he proportional dosing is inadequate and dosage
knows if the water (or other media) treated has must be realized according to the measuring
reacted satisfactorily with the chemical at the results of the water analysis. The use of
time and location of application. For the proportional dosing is also advantageous, if
treatment of potable water, a special dosing the process system is characterized by strong
pump concept was developed: Dosing pumps forces of inertia and dead times due to long
are driven by an electrical stroke solenoid flow distances through pools or pipings so that
which converts a water meter contact directly, there are long periods of time between addition
without gear reduction, into a single precise of the dosing chemical and reaction result.
dosing stroke for the addition of the chemical. Automatic controllers for a direct correction of
The immediate and reproducible controllability the reaction result (e.g. pH value) thus lead to
of the single stroke is the prerequisite for a slight oscillations caused by overdosing and
homogenous and reliable water treatment. underdosing. Proportional dosing follows the
Proportional dosing is fully ensured with this control signal more or less instantly in
method, because every single liter of potable dependence of the water flow and does not
water is treated equally due to a high pulse require any time for analysis or any other
frequency (6000 strokes per hour). Thanks to feedback from the process.
state-of-the-art electronics with a high
functionality, today’s solenoid-driven pumps
Wasser mit stets
Water with gleichenproperties
consistent Eigenschaften
Flow meter
Durchflußmesser
F
Dosierung proportional
Dosing zum
proportional
toDurchfluß
flow
Signal
Signalproportional
proportionalzum
to Durchfluß
flow
Dosierpumpe
Dosing pump
Chemical supply
Dosiermittel tank
- Vorratsbehälter
The aforementioned explanations refer to the dosing of liquids as well as to the dosing of gas or
solids.
12
0.2.4 Dosing pumps as correcting elements in automatic control systems
To obtain a certain water quality (or certain a dosing system which analyses the actual
properties of other process media) it may be water quality and determines the amount of
necessary to add differing quantities of chemical to be dosed accordingly. The
components to the same amount of water. following example serves to explain the
Therefore proportionally dosing is not suitable difference between proportional dosing and
for such an application. Water with extremely dosing with feedback:
varying properties must therefore treated with
Proportional dosing
Water with consistent properties is taken from volume of water is supplied with the
one spring. A dosing system for adding a corresponding chemical quantity. Because of
disinfectant is therefore controlled the constancy of the incoming raw water
proportionally ensuring that the appropriate quality, the right treatment is guaranteed at
quantity is dosed at maximum water flow. Due any time for any volume of water (see section
to the linear dosage proportionality, each 0.2.3).
Controlled dosing
In the second example, the water comes from the water quality. To solve the problem a
different springs and, besides, is mixed with control method is needed which measures the
varying surface water. In this case, a flow actual water quality and adjusts the dosing rate
signal cannot indicate the necessary quantity correspondingly by means of a controller. Thus
of chemical to be added, because very the dosing process is determined exactly by
different amounts of chemical per cubic meter the quality of water prevailing at any point of
may be required due to the great dispersion of time.
Dosierung
Dosage Measurement
Messung
Dosing pump
Dosierpumpe
Controller/set value
Regler/Sollwert
Chemical supply
Dosiermittel tank
- Vorratsbehälter
The controller adjusts the stroke frequency or stroke length and thus the quantity dosed per stroke.
13
0.2.5 Volumetric dosing
In chemical and process technology mostly the room temperature, the density thus defined
mass of the materials to be handled or also ensures a constant mass flow at a
produced is of significance. Volumes are constant volume flow (for this reason the
important as far as they concern the calibration pressure and temperature are
dimensioning of the piping systems, tanks and mostly engraved on float element-type flow
reactors and, of course, the selection of the meters).
dosing units. It would be logical if the dosing In the case of bulk material, the density of the
units supplied the materials according to the individual particles is constant but the effective
required mass. As for liquids the density and density of the overall mass depends on
thus the mass specific to a certain space are whether it is loosely poured or firmly tapped.
constant in most cases, it is sufficient to Besides, hygroscopic effects must be taken
determine the dosing rate volumetrically. If a into account which may change the specific
fairly precise reproducibility can be ensured, gravity of the bulk material considerably due to
this method is preferred due to its simplicity. a high water concentration. The process
Whereas with liquids the mass is sufficiently engineer has to decide whether the mass of
constant at a given volume, with gases it is the bulk material to be handled is sufficiently
extremely dependent on pressure and constant or whether gravimetric dosing is more
temperature. Therefore chlorinators must take suitable because of the great dispersion.
the following three parameters into account:
pressure, density and temperature. By
maintaining a constant pressure normally at
14
1.0 Dosing units for liquids
1.1 General principles of liquid dosing pumps
With regard to the economic efficiency when e.g. every second. Note: If the very small
comparing technical expenditure and result, volumes per second are still disturbing, it is
volume dosing units according to the positive possible to produce a uniform flow using
displacement method prevail for dosing liquids. special fittings (e.g. pulsation dampeners).
For the process the mass dosed is of Different mechanical methods are suitable for
importance but, with an assumed constant quantization. One of them is the use of gear
density, it is proportional to the volume. Liquid pumps. Every tooth space accommodates a
dosing equipment must therefore be suited to defined quantity of liquid which is also dosed
meter constant units of volume. A specific against high pressures. The dosing rate is
quantity can be considered as one large mainly reduced by gap leakage occurring
volume or many small equal volumes. One between toothed wheel and housing. The
large volume would e.g. be the filling and losses decrease with a higher viscosity. For
emptying of a tank at constant intervals. This this reason gear pumps are more suitable for
method is, however, not suitable for many more viscous media. For dosing suspensions
processes, especially because it is not (abrasive particles, wear!) gear pumps should
possible with this system to dose the chemical not be used. At constant speed of the toothed
against higher pressures. Therefore dosing wheels, dosing is constant with regard to time.
units were developed which divide the large A completely different method is the
volume into a multitude of small equal volumes peristaltic pump which meters the chemical
and which, due to energy supply, are able to to be dosed by separating a specific quantity in
dose the chemical even against highest a tube between two pressure rollers and then
pressures. The volume is “quantized” by displacing it with the turning rollers from the
injecting the chemical once or twice per suction to the discharge side. Naturally these
second into the process. Thus dosing is pumps are only suitable for low pressures
“quasi-continuous”. If a process requires daily (approx. 5 bar), as the tube would expand
60 liters of sulphuric acid per hour, adding considerably at high pressures (reduced flow
spontaneously 60 liters after one hour could rate) or could not be pressed easily anymore
already be referred to as dosing. The question when using more solid tubes.
is whether the process allows this procedure. It is an advantage that this type of pump does
Continuous processes mostly require a not require any valves and can be used for
uniform addition and therefore dosing units effervescent media without additional
which, in this case, supply the 60 liters per equipment.
hour so that an equal unit of volume is dosed
15
Eccentric spiral pumps and screw pumps media (suspensions) and show increased gap
also displace defined dosing volumes per unit leakage at higher pressures. They are very
of time but they are more sensitive to abrasive suitable for more viscous, greasy media.
Screw pump
Liquid dosing can also be realized by using controllers and control valves to set the
flow meters to continuously measure the required flow (dosing rate). For flow rates of
medium under pressure or displaced with the several m³/h, such a method may be more
help of an auxiliary pump, and by using reasonable than dosing pumps.
zuProcess to be
behandelnder treated
Prozeß
Dosierung SetSollwert
value der
of
Dosing
Dosierleistung
dosing rate
F
Regler
Controller
Auxiliary
Hilfspumpe
pump
Chemical -supply
Dosiermittel tank
Vorratsbehälter
16
Self-regulating orifice plate
A reasonable method to achieve constant orifice changes in dependence of pressure
dosing is the use of a “self-regulating orifice differences causing the plate to bend.
plate“. The flow remains constant since the
According to previous experience some of the The dosing pumps used most frequently all
known pump systems are unsuitable or only over the world are diaphragm dosing pumps,
insufficiently suitable as dosing pumps. E.g. all piston dosing pumps and the combination of
centrifugal pumps are unsuitable because they both, referred to as piston-diaphragm pumps.
are dynamic displacement systems and thus These pumps, their applications and
extremely dependent on the pressure accessories will be described in detail in the
conditions on the suction and discharge side. following chapters.
The Q (flow rate) – H (head) curve shows this.
Q-H-Kurven
Comparison imofVergleich
Q-H
curves
Förderleistung [l/h]
4
3
2
Gegendruck
Backpressure[bar]
1 Kreiselpumpen
21Membran-Dosierpumpen
Centrifugal pumps
32Kolben-Dosierpumpen
Diaphragm dosing pumps
3 theoretische
4 Piston dosingKennlinie
pumps
4 Theoretical characteristic curve
Drive (Motor)
Antrieb (motor)
Discharge valve
Druckventil
Steuerung
Control
Dosierkopf
Dosing head
Suction
Saugventil Base
Fußsockel Gear
Getriebe
The aforementioned modules are available in a multitude of versions according to the versatile
requirements of the different applications.
17
Drive
The drive supplies the energy which is varying load. If the dosing process requires
required to displace the dosing medium more accuracy, fittings can be used to make
through the piping system against friction and sure that the load of the motor remains the
operating pressure. Three-phase motors are same at any time and thus the average speed
mainly used as drive since they normally rotate is not affected.
at a sufficiently constant speed, even at
Motor characteristic
Md [Nm]
MKipp
MAnl
Mmax
Mmin
n [min-1] d a
c b
MAnl = starting torque Mmax = max. torque
MKipp = breakdown torque Mmin = min. torque
a = no-load speed
b = operating speed on lower load (e.g. rear dead center of the crank drive)
c = operating speed on higher load (e.g. 90° position of the crank drive)
d = change-over point at which the motor speed decreases considerably and overheating occurs.
To adjust the flow rate via the pump stroke larger surface of which allows enough heat to
frequency, i.e. the motor speed, frequency dissipate.
converters are used. Nowadays d.c. motors In the case speed-controlled three-phase
with thyristor controllers are only applied rarely motor, a PTC resistor monitoring the coil
for speed control, although these offer a much should be installed for safety reasons.
wider control range than three-phase motors, Due to economical reasons, often three-phase
especially in connection with tacho feedback of motors are operated with starting capacitor
the motor speed. designed as Steinmetz connection in the case
Caution! Contrary to centrifugal pumps, of single-phase mains supply. Here it has to be
dosing pumps need practically the same taken into account that the torque is thus
torque at any speed. The maximum torque is reduced to less than 25 % and that the dosing
already required when starting from standstill. pump might not start at all or restart after a
Besides, in the case of three-phase and d.c. power failure.
motors, the cooling effect of the fan wheel is For flow rates of up to 100 l/h the so-called
missing at low speeds below 50 % due to solenoid-driven dosing pumps which do not
operational conditions. Therefore an additional need any gear or rotary parts have been
motor fan (separate fan) must be installed to successful worldwide in addition to the motor-
ensure sufficient cooling. This becomes driven dosing pumps. A d.c. stroke solenoid
necessary when the dosing pump is applied as allowing to control each individual dosing
correcting element in connection with a stroke is used for energy supply and
controller. It can be checked from case to case movement of the dosing diaphragm. Thus very
whether it is possible to do without the precise, proportional dosing is possible which
separate fan by using an oversized motor the can be controlled by contacts (e.g. of a water
meter) or other signals.
18
Schematic diagram of MAGDOS
Membrane
Diaphragm
Dosing head
Dosierkopf mit Saug-
with
und suction and
Druckventil
discharge valve
Drain pipe
Dränagerohr Anschlußkabel
Connecting cable
Steuerelektronik
Control unit
The principle of the solenoid drive is limited mainly operated as sludge pumps for large
technically and economically to capacities of volumes. These drives are also found in
approx. 100 l/h against 1.5. bar. potentially explosive installations because they
The use of hydraulic and pneumatic drives is can be controlled without current.
restricted. Pneumatic diaphragm pumps are
Gear
The gears of most commercial dosing pumps used for capacity adjustment because the flow
are designed to reduce the rotating movement rate is extremely dependent on the
of the drive motor via a single-stage worm backpressure in the case of lower settings.
wheel set to the speed of the required stroke Spring-loaded tappet gears show produce a
frequency and to convert it into an oscillating sinusoidal curve only at 100% performance. At
movement. The oscillating or back and forward reduced power they are stopped or accelerated
motion is produced by an eccentric. In the case abruptly, thus causing a rather impulsive dosing
of simple pumps and those of lower flow rates behaviour. Compared to other methods, the
up to 1,000 l/h, the eccentric is scanned by a relatively reasonable construction is
spring-loaded tappet moving the piston or advantageous. With regard to hydraulic
diaphragm. For the capacity setting of the aspects, it is also an advantage that the
dosing pump, an adjustable stop is used which diaphragm or the piston always reaches the
limits the return action of the tappet. Thus a front dead center, even at reduced stroke
continuous adjustment of the stroke length is settings, and thus minimizes the clearance
possible between 0 and 100%. In practice only volume.
a stroke length of more than 10% should be
19
11Membrane
Diaphragm 11 10 9
22Membranflansch
Diaphragm flange
33Feder
Spring
44Stößel
Tappet
55Verstellknopf
Adjusting knob
66Feststellknopf
Locking knob
77Hubbegrenzung
Stroke limiter
8 Exzenterlager
98Schneckenrad
Eccentric bearing
9 Worm wheel
10 Exzenterwelle
10Schnecke
11 Eccentric(von
shaft
Motorwelle)
11 Worm (of motor shaft)
1
8
5 7
2
3 4 6
Tappet
Stößel
Rückholfeder
Return spring
Anschlag
Stop
Hub-Verstellung
Stroke adjustment
0 100% 0 100%
20
Output diagram of a tappet gear
Capacity setting
Mengeneinstellung
11Leerlauf
No-load operation
des Exzentersof the eccentric
2 Suction stroke
2 Saughub
3 Discharge stroke
3 Dosierhub
4 No-load operation
4 Leerlauf
1 2 3 4
Full stroke
Vollhub
Exzenter with
Eccentric mit Zahnstangenverstellung
continuous
rack adjustment
stufenlos
Hub/2
Stroke/2 kein Hub
No stroke
Stroke
Hub
Hub
Stroke
100% Dosierung
100% dosage
Reduced dosage
reduzierte Dosierung
Kurbelweg
Distance covered by crank
The drive consists of an oil-filled worm gear crank pin. The stroke length of the tappet or
with single-stage reduction. The main connecting rod gear can be adjusted manually
component of the KARDOS gear is the radially or remotely using a servomotor. Most
movable eccentric. It can be adjusted servomotors are operated electrically but they
according to the required flow rate by means can also be activated pneumatically (adjusting
of the helical rack. It is an advantage that there cylinder). For batch control the pump gears
is no apparent sliding motion between the can be equipped with a stroke count
parts after completion of the stroke mechanism. Thus the pump can be switched
adjustment. The eccentric acts like a fixed off after a preset number of strokes.
21
Dosing head
In many respects, the dosing head is the most measures such as providing spring-loaded
important part of a dosing pump. It is not only balls or valve disks support the valves in
required to meter the volume precisely but closing more quickly and thus ensure perfect
must also be resistant to extremely aggressive dosing. Substances which are not fluid
media. In some cases the dosing head must anymore at room temperature (e.g. congealed
be suited to withstand very high operating fat, tallow, molasses or bunker fuel) must be
pressures and temperatures exceeding 100°C. warmed up until flowability by heating dosing
If toxic, volatile or abrasive media must be head and valves before startup. Of course,
dosed, the dosing head should be leakproof. heat must also be applied to the suction and
Highly viscous media affect the valve function discharge lines to ensure that the medium
so that the valves close with delay. Special remains fluid.
Packing
Packung
Deflector plate
Abweiserscheibe
Piston
Kolben
Stopfbuchse
Gland
Diaphragm
Membrane
Gland nut
Stopfbuchsmutter
Drainage
Dränage
Doppelkugel-Saugventil
Double-ball suction valve
22
Hot water or steam
3 4
Spring-loaded Spring-loaded
single-ball valve disk valve
2 5
6
5 4
4 3
7 2
1
2 1
8
Double-ball valve
2
6 1 Valve seat
2 2 Washer
7 3 Valve disk
1 4 Valve housing
5 Spring
4 6 Ball guide
8 7 Valve ball
8 Plug
Displacement elements
The standard displacement elements are and the operating conditions, both have
dosing diaphragm and piston. Depending on advantages and disadvantages which will be
the task, i.e.: the type of medium to be dosed explained in the following:
23
Diaphragm
The main advantage of a diaphragm is that it is up to 10 bar. Special constructions or
absolutely leakproof so that no toxic, operating modes with an accepted service life
aggressive or ecologically harmful media can reduction allow pressures of up to 20 bar. The
escape to the environment. Besides, the diaphragms are made from fabric-reinforced
diaphragm is mostly insensitive to abrasive rubber such as EPDM, Hypalon or Viton. To
media. It is also safe to run dry although this increase resistance, the diaphragms are
advantage becomes effective only if available with a teflon coat. The thickness of
remainders of the chemical do not tend to the coat represents a compromise with regard
crystallize due to air entering the valves (the to non-porous teflon and rigidness restricting
latter can, however, be avoided by a level the diaphragm movability. To improve the
control installed in the chemical supply tank). performance curve (linearization in
The disadvantages are mainly that the flow dependence of the stroke length) and to
rate depends more or less on the pressure and increase the flow rate, diaphragms can also be
that there is no linear relationship between reinforced by so-called “support plates”. A
stroke length and flow rate (half the stroke round metal part is vulcanized with threaded
does not necessarily mean half the output). stem to attach the diaphragm to the gear
Normally dosing diaphragms can only be used tappet.
Membrane
Diaphragm
Deflector plate
Abweiserscheib
l/h 1 bar
5 bar
10 bar
Hub %%
Stroke
Piston
Piston pumps can operate against several 100 chemical by flushing the lantern ring of the
bar and the flow rate is rather independent of packing intensely with water so that the
the backpressure. Furthermore there is a very leakage escaping to the environment contains
linear relationship between stroke length and no more than a low concentration of the
flow rate. A disadvantage is, however, the problematic chemical. Flushing, however,
leakage which is in fact necessary to lubricate depends considerably on the local conditions
the packing. Dry operation is not allowed. Dry and on the type of medium. For abrasive
friction between piston and packing would media, it might be useful to build up a pressure
cause local overheating and scoring with higher than the operating pressure at the
increasing leakage. The use of toxic and flushing lantern ring so that possibly entering
extremely aggressive media is impossible particles are pushed in the direction of the
because of the leakage. There is, however, the medium.
possibility of dosing the aforementioned type of
24
Spülwasseraustri
Outlet of flushing water
Kolben
Piston
Laternenspülun
Lantern flushing
l/h
1 bar
200
Hub %
l/h Vergleich des
Comparison of Förderverhaltens
the discharge behaviour
Kolben-Dosierpumpen
Piston dosing pumps
Hub % %
Stroke
The conflict situation between aggressiveness diaphragm dosing pumps. This type of pump
on the one hand requiring leakproof operation combines the precision and high discharge
and high operational pressures on the other pressures of piston pumps with the leakproof
hand making the use of simple diaphragm operation of diaphragm pumps.
pumps impossible is solved by piston-
25
Piston-diaphragm system KMS with glycerin or silicon oil (without air). Thus
The “piston-diaphragm“ system combines the the diaphragm is forced to displace the same
advantages of diaphragm pumps and piston volume as the piston, and the medium on the
pumps without including their disadvantages. other side of the diaphragm will be moved in
The function of the piston-diaphragm system is the same way. To compensate for the liquid
most easily to understand if we imagine the lost at the piston due to leakage, a blow valve
cylinder of the piston pump to be hermetically ensures that the missing quantity can be
sealed from the actual dosing head by a reprimed. At the same time a pressure relief
diaphragm. To transmit the volumetric valve causes surplus glycerin or silicon oil to
displacement of the piston to the medium side, flow back to the supply tank in the case of
the gap between piston and diaphragm is filled excess pressure.
Discharge valve
Druckventil
Medium
Piston
Kolben
Packing
Packung
Glycerin
Glycerin
Membrane
Diaphragm
Suction valve
Saugventil
Glycerin
Degassing valve
Diaphragm
Bellow pump
Regarding the effect, the bellow pump lies eccentric. Bellows are leakproof and have a
between piston-diaphragm pump and normal rather linear performance curve (similar ot a
diaphragm pump.Instead of the diaphragm, it piston). Unfortunately this principle is only
is fitted with bellows similar to those of a suitable up to 5 bar due to the mechanical
concertina, which are changed in length by the strength of PTFE which is used in most cases.
26
Tappet
Bellows
Faltenbal
Dosing head g
Dosierkop
27
1.2 Lutz-Jesco dosing pump program
In addition to the sales literature folder, a below schematic diagram divides the Lutz-
general idea of the dosing pump program will Jesco product range for liquids in diaphragm
be given in the following. For more detailed dosing pumps, piston dosing pumps and
technical information, refer to the brochures, piston-diaphragm pumps.
data sheets and operating instructions. The
head:
980 MEMDOS MR
380 MEMDOS DX
850 KARDOS KN
KMS-piston-
380 MEMDOS E
head:
REKOS KR
piston-
diaphragm-
MINIDOS A
40 FEDOS TK
4200 KARDOS N
FEDOS K
850 diaphragm
MAGDOS
Pump
Pump Typ
type
Dosing
dosing
KMS
Function
Function:
725
40
100
24
manual x x x x x x x x x x x
Stroke adj. o o o o o o o o o o
electrical
Speed adj. manual x
electrical o o o o o o o o o o o
manual x x
Stroke freq.
electrical o x
Controllable by directly x x
contact Separate electronic unit
x x x x x x x x x x
Three-phase motor
o x x o o o o o
D.C.-Motor x x x x x x x x x x x
Drive GS-Motor o o o o o o o o
EX-Motor o o o o o o o o o
Solenoid x
max. number of dosing 1 1 1 1 2 2 2 2 2 12 6 6
h d
28
Schematic diagram of frequency converter for speed control
Variable drive speed, constant stroke
Frequency converter with manual adjustment by poti
or
impressed direct current 0(4)…20mA
Control “left-stop-right”
ATE
Make sure that the stroke of the servomotor is contact must be provided. In the case of non-
never adjusted during standstill of the drive observance the gear of the servomotor may be
motor. For this purpose, an electrical locking damaged.
L1
Auf
Open Zu
Closed
N
PE
ATE servomotor
ATE-Servomotor
16 2 1 3 17 10 11 12
29
With regard to control-relevant aspects, it must systems, it is almost irrelevant whether there is
be considered, that the servomotor completes a linear relationship between signal and flow
the stroke adjustment much more slowly rate, as the controller adjusts the dosing pump
compared to the effect achieved by changing until the actual value matches the set value.
the speed of the drive motor. It is another Most gear versions of motor-driven pumps are
advantage of speed adjustment over stroke tappet gears with single-stage worm wheel
adjustment via servomotor that a better reduction. Crank gears with connecting rod are
linearity between signal and flow rate is only used for GMR diaphragm pumps and
ensured. Half the speed corresponds to half KARDOS piston pumps. While the stroke of
the flow rate, independent of whether a the GMR is always constant and the speed is
diaphragm dosing pump or piston dosing pump variable, the eccentric of the KARDOS can be
is used. As already described in previous adjusted continuously. Thus a uniform sinusoid
chapters, diaphragm metering pumps do not is constantly repeated, but with variable
have a linear relationship between stroke amplitude. The dosing ranges start at
length and flow rate. Therefore half the stroke 0 … 0.1 l/h for solenoid pumps and end at
length does not necessarily mean that also half 4,200 l/h per head for the largest diaphragm
the quantity is dosed. This must be taken into pump as well as for piston pumps. With the
account if the dosing pump is operated without exception of the solenoid dosing pumps and
feedback in an open control system, e.g. in the MEMDOS E/DX, all dosing pumps are
case of proportional dosing according to a flow available with single or duplex head, the
meter signal. KARDOS can also be supplied as multiple
Note: If the dosing pump is used as a head pump. See above table.
correcting element in automatic control
30
Characteristic curves of different dosing pumps which all have an output of 100 liters over the same
period of time.
The hatched areas represent 100 liters.
Characteristic curves
l/h
105
Triple head dosing pumps, with the
total flow rate being divided into thirds
and each head dosing
3.14*33.3 = 105 l/h
1.3 Fittings and accessories
In many cases the dosing pump alone cannot take place or the pump achieve maximum
perform the set task. Then auxiliary equipment accuracy. The following situations may require
and fittings are required in addition to optimize supplementary measures:
the hydraulic conditions so that dosing can
Operating condition of the dosing Recommended fitting
system to be improved or installation
1. Priming is facilitated if the volume primed Use suction line with foot valve
after a stroke cannot run back in the suction (ball non-return valve)
line but remains at the level reached before. and additionally protective strainer
+ Install priming aid close to suction valve of the
dosing pump.
Provide pressure relief at the pressure joint of the
suction pump. For this purpose either the
multifunction valve PENTABLOC or a manually or
electrically operated dosing head venting, e.g.
GAS-EX, can be used.
Provide siphon with hand vacuum pump or
manually or automatically activated injector.
3 Dosing pump often have large dead centers. Install manual or automatic degassing device
Therefore included air immediately has a GAS-EX or/and air bleed traps at the suction
negative effect. Dosing may fail completely. valve.
4. Varying heads in the supply tank influence Provide an intermediate receptacle (siphon-type
the flow rate. collector) with constant filling level, e.g. float valve
or suction controller SDR.
5. If the dosing line is closed by mistake or Install pressure relief valve as safety valve.
blocked up, the resulting excess pressure
may cause damage to the dosing pump or
system.
31
6. Varying backpressures affect the flow rate, Install backpressure valve for constant
especially in the case of diaphragm pumps. backpressure.
7. More chemical is dosed than defined Referring to a), b) and c):
according to the flow rate setting, Install backpressure valve at the end of the dosing
caused by the following conditions: line.
a) pressure too high on the suction side
b) vacuum at the point of injection Referring to d):
c) point of injection geodetically below the Install pulsation dampener PDS just before the
dosing pumps suction valve and backpressure valve at the end
d) Mass inertia of the liquid head due to a of the line.
long dosing line
8. The dosing chemical should be introduced Mount injection fittings ready for installation,
into the injection nozzle through a non-return consisting of shutoff valve, non-return valve and
valve so that no medium can escape in the injection pipe (down to the middle of the process
case of a dosing line rupture. pipe).
Before longer shutdown periods of the dosing
pump the shutoff valve of the injection fitting
should be closed. Do not only rely on the function
of the non-return valve!
9. Pressure and flow fluctuations of the Install pulsation dampener at the outlet of the
oscillating dosing pump are unwanted. The dosing head.
high pressure peaks resulting from the In the case of critical priming conditions (long
accelerations may affect the dosing output suction lines, high suction heads), pulsation
and the service life. dampeners mounted on the suction side will also
Float element flow meters require a uniform have a positive effect.
flow.
10. The dosing chemical tends to deposit or Fit dosing head with a flushing facility which
precipitate (sedimentation). Thus dosing lines flushes head and valves e.g. with water before
and, in the case of standstill, also valves or shutdown periods.
displacement elements may be affected.
11. The dosing chemical has congealed at room Fit dosing head and valves with heating. Current,
temperature and is no longer fluid. steam or hot water heating is possible.
Possibly also provide external heating for lines to
and from the pump.
12. Aggressive or toxic media might leak due to Install leakage sensor LECKCHECK at the dosing
a diaphragm failure. head.
13. No control if dosing takes actually place. Install visual flow control or electrical flow sensor
FLOWCON at the pump outlet.
a) The dosing head is not filled sufficiently which causes reduced flow rates.
b) The steam bubbles occurring during cavitation strike together again afterwards and lead to
mechanical destruction of the internal parts of the dosing head.
If the liquid must be primed upwards (e.g. from tank) the required suction pressure also affects
buried tanks or with pumps mounted above the filling of the head. In the case free supply, i.e.:
32
if the pump is installed below the tank level, to the nominal pump capacity (hence at
the static pressure helps to fill the head. The uniform flow). Therefore three times the max.
negative effects are reduced with shorter flow rate must be taken into account when
suction lines and larger line diameters. The dimensioning the suction line of oscillating
length of the suction line should not exceed 2m dosing pumps with motor drive.
for water-like media and the diameter should For safety reasons, five times the rate must be
allow velocities of not more than considered in the case of solenoid pumps,
0.8 m/second. For oscillating dosing pumps since the stroke is not sinusoidal but more
without pulsation dampening, the flow is not pulsed.
uniform. The top speed of single-head pumps
with eccentric drive is approximately three
times as high as would be expected according
Note:
For suction lines longer than 2 meters and line should be checked mathematically and
media with high steam pressures as e.g. dimensioned accordingly. In addition to the
methanol, the suction line and, for media of a generally available literature about hydraulics,
higher viscosity than water, also the discharge chapters 1.3.1.1 and 1.3.1.2 can be helpful.
1.3.1.1 Calculating the diameter of the suction line with due regard to the stroke frequency
To constantly ensure perfect fillling of the Positive Suction Head, available"). The
dosing head despite a pulsating operation of system-related accelerations and
the dosing pump, the pressure existing at the decelerations of the liquid head in the case of
inlet of the suction valve must be high enough oscillating dosing pumps have to be taken into
to allow the dosing chemical to flow into the account in particular when dimensioning the
dosing head at the speed required by the suction line. As the distance between dosing
piston (diaphragm) during the suction stroke. pump and tank is often fixed, the diameter
If the dosing chemical cannot follow at the must be chosen with due regard to the length
same speed, the flow “breaks off“ and of the suction line so that caviation is avoided.
cavitation occurs. The pressure existing at the The available NPSH value can be calculated
suction valve is generally referred to as the according the following formula:
available NPSHa value (abbreviation of "Net
psteam = steam pressure of the dosing chemical (bar abs) at the temperature existing
at valve entry. (Water at 20 °C has a steam pressure of 0.023 bar)
Hsuction = suction head [m] (+) for free supply (-) for upward suction
ς = density [kg/m³]
With a given NPSHa value and known stroke frequency of the dosing pump, the minimum diameter of
the suction line can be calculated using the following formula:
Q * F * L *ς
(II) d≥
8.6 * 105 * ( NPSH a − 015
. )
This formula does not take any flow losses into account.
33
Note: factor 8.6*105 compensates for measuring units,
constant 0.15 represents a safety factor in [bar]
1.3.1.2 Calculation of the pressure peak in the dosing head caused by acceleration during
discharge stroke
(III)
Q * F * L *ς
paccel. = [bar] (units see above)
8.6 *105 * d 2
The pressure peak calculated with the help of highest level at a crank angle of approx. 90°.
this formula must be added to the operating During this moment there is uniform flow, i.e.:
pressure against which dosing is to take place. no acceleration or deceleration.
The total must be below the admissible pump For the calculation of the lines, it is thus
pressure. sufficient in most cases to check the critical
The acceleration relevant for line calculation situations, i.e.: maximum acceleration and the
reaches its maximum values at the rear or pressure stroke to be expected or pressure
front dead center. As exactly at these two dead reduction until cavitation, and on the other
centers no dosing takes place, because the hand pressure loss occurring at maximum flow
displacement element (piston or diaphragm) is due to friction in pipes and fittings.
not working, at this moment there is no Also for the discharge line, it is recommended
pressure loss due to friction in the pipe. On the to calculate the pipe diameter for an
other hand the friction in the pipe is the acceptable pressure stroke.
strongest when the flow speed reaches its
Q * F * L *ς
(IV) d≥ [bar] (units see above)
8.6 *10 5 * paccel.
Note:
To calculate the frictional loss in pipes for causes the viscosity of liquids to increase), the
oscillating pumps such as diaphragm and viscosity of different liquids also shows other
piston dosing pumps, often only the nominal varying characteristics. Liquids with the same
capacity is used by mistake. It is neglected to viscosity at the same temperature, for
consider the actually occurring maximum flow example, may have a completely different
which is approximately three times as high for behaviour when moving at high speed. There
motor-driven dosing pumps and approximately are liquids which, at higher speeds, show
five times as high for solenoid pumps (see progressively increasing viscosity properties in
1.5.3.4). When using a pulsation dampener, pipings or tanks, and there are others with an
this increased flow rate only applies for the apparently decreasing viscosity. As far as
section between pump and dampener. For the dosing pumps and fittings are concerned, it is
rest of the piping, the nominal capacity can be recommended to calculate the frictional losses
taken into account. in pipes carefully according to the formulas
Especially the calculation of pressure losses and values available by technical literature. To
by friction in pipes is rather complicated, since estimate the dimensioning of the piping
it also depends on the viscosity of the liquid. roughly with due regard to acceleration, the
Apart from the fact that the viscosity is strongly formulas in chapter 1.3.1.1 can be used.
related to temperature (a low temperature
Dimensioning of the piping according to the frictional losses can be estimated roughly using the
following formulas:
1.3.1.3 Calculation of the pressure loss with due regard to friction in pipes
For a rough estimate of the pressure losses elbows, reducers, valves, etc., the following
due to pipings and inline components such as calculation model can be used:
1. Flow speed
Coming from the quantity Q to be dosed (l/h) Diagram 1.5.3.4 can be used for this
and the assumed flow speed w (m/s), the purpose.
pipe diameter d (mm) is determined.
34
2. Pressure loss ∆pA due to fittings
From the table, the drag coefficient ξ of the
individual fittings, elbows, etc. integrated in the For inline components not listed in the table,
course of piping have to be determined and use comparable ξ values.
added.
Pipe bend
Rohrbogen
r/d 1 2 4 6 10
r ζ 0,5 0,3 0,23 0,18 0,2
d Sockets,
Muffen, bushings, Reduktionen
Bundbuchsen, reductions
Elbows, sharp-edged
Kniestücke, (scharfkantig)
α 10 15 30 45 60 90
α ζ 0,04 0,06 0,15 0,3 0,6 1,2
T-piece
T-Stück
ζ = 1,3
Ein- bzw.
Inlet Auslaufstutzen
or outlet an Behältern
connection piece
Type of fitting
Armaturen-Art ζ
Ball valve
Kugelhahn 0,6
ζ = 0,06 Y-valve
Schrägsitzventil 0,6
DIN-Absperrventil
DIN shutoff valve 3,9
Eck-Ventil
Corner valve 3,0
Solenoid valve
Magnetventil 6,0
ζ = 0,56 Non-return valve
Rückschlagklappe 6,0
Clack or needle
Klappen- bzw.
flow detector
Kegel-Strömungswächter 5,8
Schwebekörper-
Float element
Durchflußmesser
flow meter 6,5
ζ = 2,8
35
Σξ * w 2 ⎛ Σξ * Q ⎞
2
(V) ∆p A = *ς = ⎜ ⎟ *ς [bar]
2 * 105 ⎝ 1,264 * d 2 ⎠
w = flow speed [m/s]
ς = density [kg/m3]
d = pipe diameter [mm]
Q = flow rate [l/h]
w * d / 1000
(VI) Re =
ν
w [m/s] = flow speed ν [m²/s] = kinematic viscosity
d[mm] = pipe diameter η [mPa*s] = dynamic viscosity
ρ [kg/m³] = density
η
ν = viscosity [m²/s] ⎯
⎯→ conversion: ν=
ρ *1000
If Re<=2320, the flow is laminar and the below formula must be used for the pressure loss factor:
(VII) λ=64/Re
If Re>2320 and thus the flow is turbulent, a good approximate calculation is possible for smooth
pipes and tubes using the following formula:
L * λ * w2
(IX) ∆p R = * ς [bar]
d * 2 * 10 2
5. Example
400 l/h saline solution is to displaced against The max. flow rate of the pump is 456 l/h
1bar system pressure using a dosing pump against max. 5 bar. The pipe diameter and
MR 400. The oscillating pump is operated with pressure losses have to be determined.
a tappet gear at 50 strokes/min and produces
a sinusoidal output.
ρ = 1180 kg/m³
ν = 2* 10
−5
[m²/s] ⎯
⎯→ η = 23.6 [mPa*s]
System design:
Dosing pump; 0.5m PVC pipe; shutoff valve piece, 4m PVC pipe. Roughness of the piping:
(DIN valve); 30m PVC pipe, solenoid valve; 0.01 mm.
flow detector; elbow; flow meter, elbow, T- System pressure: 1 bar
36
Solution:
Because of the oscillating operation, the nominal flow capacity must be multiplied by 3. 456 * 3 = 1368
l/h
According to diagram 1.5.3.4, the pipe diameter is 16 mm at a velocity of 1.89 m/s.
Σξ = 24.5
L * λ * w2 34,5*,0423 * 1,89 2
∆p R = *ς = * 1180 = 1.92 bar
d * 2 * 10 2 16 * 2 * 10 2
Σξ * w 2 24.5 * 1,89 2
∆p A = *ς = * 1180 = 0.52 bar
2 * 105 2 * 105
Note:
2.44 bar are admissible for the pump, But how about acceleration? According to
as the pressure is still below 5 bar (max. formula (III), chapter 1.3.1.2, the acceleration
allowed backpressure) despite the system pressure amounts to
pressure of 1 bar.
Thus the allowed pressure is exceeded and the diameter must be recalculated taking this aspect into
account:
Q * F * L *ς
According to formula (IV) , chapter 1.3.1.2: d≥
8.6 *10 5 * paccel
456 * 50 * 34,5 *1180
d≥ = 32.85 → DN32 would produce pressure peaks of max. 1bar.
8.6 *105 * 1
If a pulsation dampener was used, the flow acceleration do not occur and the friction of the
would be rather uniform and the average flow 16 mm pipe is determined as follows:
rate would correspond to the nominal pump According to the diagram 1.5.3.4, the velocity
capacity of 456 l/h. Pressure peaks due to is 0.63 m/s for a 16 mm pipe.
The pressure loss in the piping amounts to:
37
w * d / 1000 0,63 * 16 / 1000
Re = = = 504
ν 2 * 10 −5
λ = 64/Re = 64/504 = 0.127
L * λ * w2 34 ,5*,127 * 0,632
∆p R = *ς = * 1180 = 0.64 bar<< 5 bar
d * 2 * 10 2 16 * 2 * 10 2
Due to the use of the pulsation dampener, the nominal width can be DN16 in this case.
Refer to chapter 1.3 “Fittings“.
Foot valve
1
1 Ball guide
2 2 Ball
3 Seat
3
4 Filter
4
If the pump is located at or below the level of tank is not transmitted to the pump and thus
the tank bottom and if a connection at the affects the dosing accuracy or causes
bottom of the tank is admissible, no foot valve excessive dosing and siphoning of the tank.
is required. In this case, however, a shutoff Required fittings such as backpressure valves
valve and a filter should be provided to keep are described in chapter 1.3.4.
away impurities from the pump valves. It must
also be ensured that the liquid pressure of the
38
1.3.2.2 Suction lines for non-returnable containers
Many chemicals and products are sold in supply from these non-returnable containers, a
easy-to-handle containers between 30 and 60 specific suction line was developed. It has the
liters. Also the covers are standardized in most following advantages:
cases (e.g. size K 60). For direct chemical
The suction lines with integrated level control solenoid dosing pumps to switch these without
can be connected directly to Lutz-Jesco an additional level relay.
3 4+5
6
1 Protective pipe
2 2 Sealing cap
8 3 Tubing connection
4 Connecting piece for medium
from non-return valve
5 Connecting piece for medium
from automatic degassing valve
6 Low level control plug
1 7 Suction nozzle
8 Non-return valve
9 Cable for low level indication
10 Float (alarm signal)
11 Reed switch contact
12 Float (tank-empty signal)
10
11
7 12
39
1.3.3.1 Siphon-type collector and priming aid
There are mainly two reasons for installing priming aid before the suction valve:
a) Easier priming
On startup, dosing pumps with lower flow rates the efficiency. As a result of the reduced level
are not able – due to the low suction volume - in the collector, a vacuum is produced which
to produce a vacuum allowing the liquid head makes a permanent supply from the chemcial
in the suction line to reach the dosing head. In tank possible. If there is no degassing (see b),
this case the first filling of the siphon-type the collector does not need maintenance for a
collector enables the pump to prime directly long time.
and is used to wet the valves and to improve
b) Gas separator
Collection of gas or air which is released by clearance volume effect. If the liquid in the
the medium or enters the suction line during collector is displaced by the gas, it must be
the replacement of a non-returnable container refilled.
and which may interrupt dosing due to the
Dosing liquid
Dosierflüssigkeit
ist
is sichtbar
visible
to suction valve
zum Saugventil
of pump
der Pumpe
Saugleitung
Suction line
LL[m]
[m] von
fromFußventil bisto
foot valve Ansaughilfe
priming aid
H H
40
The following table applies 1bar abs. air V=Bx(DN)². The volume thus determined
pressure and constant nominal width for the includes approx. 20% allowance and enables
complete piping. The required collector volume the pump to prime medium up to height H.
for any pipe diameter is calculated by
Suction head Overall line Density Min. Min. volume of the collector
H[m] at length [kg/m3] volume at line diameter DN
almost L[m] starting B[dm3] [dm³]
empty tank at valve for DN1 4 6 10 16 25 40
1 2 1000 0.00115 0.02 0.04 0.11 0.3 0.7 1.8
1 2 1500 0.00127 0.02 0.05 0.13 0.3 0.8 2.0
1 2 2000 0.00140 0.02 0.05 0.14 0.4 0.9 2.2
1 5 1000 0.00146 0.02 0.05 0.15 0.4 0.9 2.3
1 5 1500 0.00176 0.03 0.06 0.18 0.4 1.1 2.8
1 5 2000 0.00209 0.03 0.08 0.21 0.5 1.3 3.3
2 3 1000 0.00258 0.04 0.09 0.26 0.7 1.6 4.1
2 3 1500 0.00306 0.05 0.11 0.31 0.8 1.9 4.9
2 3 2000 0.00371 0.06 0.13 0.37 1.0 2.3 5.9
2 6 1000 0.00327 0.05 0.12 0.33 0.8 2.0 5.2
2 6 1500 0.00424 0.07 0.15 0.42 1.1 2.7 6.8
2 6 2000 0.00554 0.09 0.20 0.55 1.4 3.5 8.9
3 4 1000 0.00440 0.07 0.16 0.44 1.1 2.7 7.0
3 4 1500 0.00581 0.09 0.21 0.58 1.5 3.6 9.3
3 4 2000 0.00822 0.13 0.30 0.82 2.1 5.1 13.2
3 6 1000 0.00519 0.08 0.19 0.52 1.3 3.2 8.3
3 6 1500 0.00730 0.12 0.26 0.73 1.9 4.6 11.7
3 6 2000 0.01092 0.17 0.39 1.09 2.8 6.8 17.5
4 5 1000 0.00681 0.11 0.25 0.68 1.7 4.3 10.9
4 5 1500 0.01051 0.17 0.38 1.05 2.7 6.6 16.8
4 5 2000 0.02096 0.34 0.75 2.10 5.4 13.1 33.5
4 8 1000 0.00864 0.14 0.31 0.86 2.2 5.4 13.8
4 8 1500 0.01456 0.23 0.52 1.46 3.7 9.1 23.3
4 8 2000 0.03127 0.50 1.13 3.13 8.0 19.5 50.0
5 6 1000 0.01016 0.16 0.37 1.02 2.6 6.3 16.3
5 6 1500 0.02046 0.33 0.74 2.05 5.2 12.8 32.7
5 6 1750 0.03899 0.62 1.40 3.90 10.0 24.4 62.4
5 10 1000 0.01379 0.22 0.50 1.38 3.5 8.6 22.1
5 10 1500 0.03095 0.50 1.11 3.10 7.9 19.3 49.5
5 10 1750 0.06184 0.99 2.23 6.18 15.8 38.6 98.9
6 7 1000 0.01509 0.24 0.54 1.51 3.9 9.4 24.2
6 7 1500 0.05540 0.89 1.99 5.54 14.2 34.6 88.6
6 12 1000 0.02284 0.35 0.79 2.18 5.6 13.6 34.9
6 12 1500 0.09093 1.45 3.27 9.09 23.3 56.8 145.5
1.3.3.2 Siphon
To overcome high suction heads may become line. The pump is subject to the supply
difficult even for larger pumps if effervescent pressure depending on the tank filling level. As
media have to be dosed. This applies soon as the upper part of the suction line is
especially if the medium is not supplied freely filled with gas, the hydraulic balance is not
to the pump via a suction line connected at the ensured anymore. The pump must then prime
bottom of the tank but must be primed over the more and more in dependence of the tank
edge of the tank. The system is balanced height. This may lead to the failure of the
hydraulically if no air is enclosed in the filled pump. Thus a system has been successful
41
which, from time to time, primes liquid collector (siphon). As a result gas can only
manually or by means of a vacuum pump accumulate outside the suction line, and the
(manually operated pump or injector) from the communicating effect of the suction line is
supply tank into a controllable intermediate ensured continuously.
Hebesystem
Siphoning für Saugleitungen
system for suction lines
Druckluft
Compressed air
Injektor
Injector
V1
Exhaust
Abluft air
Level
Niveaucontrolled
geregelt
or
oder
adjusted
von Hand manually oreingestellt
mit Ventil V1 via valve V1
2. Intermediate tank the bottom level or lower than the supply tank.
It is, however, also possible to use an The dosing pump then primes liquid from the
intermediate tank controlled via float valve. intermediate tank with an always constant
This intermediate tank must be positioned at level.
42
1.3.4.2 Suction controller SDR 50
Constant suction pressure and leakage stop
Dosing pump which are mounted above the In installations with a free supply to the pump,
tank (e.g. buried tanks) or also below the tank the danger of leakage from the tank is given in
deliver less the more the tank gets empty, the case of a diaphragm or line rupture.
because either the suction lift increases or the Under normal conditions dosing pumps must
positive suction head decreases. not be fed directly from pressure lines,
Dosing pumps with large diaphragms can because a pressure of e.g. 2bar multiplied by
develop a remarkable force on the stroke the effective diaphragm area might exert
adjusting mechanism, if tanks and density (e.g. destructive forces on the pump gear. On the
sulphuric acid) are particularly high. other hand overfeeding would take place if a
As a result of the mass moment of inertia of backpressure valve was not installed on the
the liquid in motion, in long suction lines discharge side or wrongly adjusted.
overfeeding can occur if the diaphragm or also In the case of long suction lines, cavitation can
the piston suddenly stops at the stroke limiting result in reduced flow rates or the destruction
stop. Even if backpressure valves avoid of fittings due to the oscillating operation of
overfeeding on the discharge side, a force dosing pumps.
which increases wear is produced at the stroke
adjusting mechanism of the pump and on the
suction side of the system.
The aforementioned problems can be solved by one single fitting: suction controller SDR50
The suction controller is a spring-loaded an almost empty tank. Thus the pump has to
diaphragm valve which can only be opened by prime all the time as if the tank was empty and
the suction pressure of the dosing pump. Thus is hardly affected by actual filling level or
it is ensured that no medium can flow if the suction head.
pump is not working or cannot create a The flow in the suction line due to the mass
vacuum due to a leaking suction line. moment of inertia is stopped will be stopped in
An undesired suction effect at the pump outlet the suction controller, if the pump does not
must be avoided by means of backpressure carry out a suction stroke. In this case the
valve. suction controller must be installed directly in
Depending on the individual operating front of the pump inlet in order to avoid
conditions, the required maximum vacuum pressure impacts.
can be set up to 300mbar using an adjustable If the suction controller is to be used as a
spring. For pumps with a positive suction head, leakage stop for the tank, it must be installed
it is sufficient to set a very low vacuum of at the tank, if possible, or close to it in a
approx. 50mbar. This vacuum must be created mechanically protected position. In the case of
by the pump in any case, even with a a suction line rupture, the suction controller
pressureless supply. closes immediately by spring force, since the
pump cannot open the suction controller
At a supply pressure of e.g. 1bar, anymore due to the broken line. Supply
corresponding to a tank height of 10m and a pressure exerted on the closing element
liquid density of 1,000 kg/m³, the vacuum for supports the closing function.
the pump is increased by only approx. If the suction controller is installed before the
100mbar. pump, priming by the pump becomes easier
For emptying buried tanks or in the case of because the liquid volume below the controller
installations where the pump is located above diaphragm is directly available at the pump
the tank, the vacuum required for dosing is set when priming is started.
to the highest occurring vacuum by means of
the adjusting spring. This value corresponds to
Caution!
If the dosing line between the pump and the backpressure valve must be installed at the
process is under vacuum or tends to siphon end of the line.
because of the geodetic conditions, a
43
Cross sectional view of the suction controller
6
3 2
5 7 4
The liquid coming from left first faces a shut because then the reduced volume between
valve (ball/seat 2+3), which is closed by the diaphragm (5) and ball (2) causes the
spring (1) and sealed additionally by the liquid atmospheric pressure entering through the
pressure. Thus liquid can only flow if the ball drilled compensating hole (7) to push the
(2) is pushed down by the plunger (4). This diaphragm (5) with the plunger (4) against the
happens only if liquid is drawn off to the right, ball (2).
44
Installation
The installation location of the suction fixed to the wall using a pipe clamp. The
controller SDR50 depends on the application. operating position is arbitrary but entry of dirt
Due to its low weight, the controller can be or water into the drilled pressure compensating
mounted freely in the case of rigid lines or hole (7) should be avoided.
Possible applications:
a) Protection of the metering pump against excessive supply pressure due to high tanks or supply
from pressure lines
b) Avoiding siphoning
c) Avoiding varying positive and negative suction heads which affect the dosing accuracy
d) Protection of the dosing pump against pressure peaks due to acceleration in the case of long
suction lines
e) Use as leakage stop for tanks in the case of diaphragm or line rupture
1
1
2 3
3
2
4
4
3
2
4
1
1
2
3 3
2
4 4
Dosing head
Ball
Valve stem
Lock nut
Drain sleeve
In the case of integrated dosing head venting, discharge the gas without pressure against
the valve is turned to the left by half a atmosphere until liquid appears. Then the
revolution for starting or venting. Thus the ball valve is closed tightly again.
is lifted from the seat and the pump can
Non-return valve
Rückschlagventil
Ventilspindel
Valve stem
Arretierung
Lock nut
Dränage
Drain sleeve
46
Electrical degassing device GAS-EX
In the case of the degassing device GAS-EX, a takes place in between at fixed times, the
solenoid valve is opened e.g. every 30 system is depressurized so that possibly
seconds for 2 seconds. Thus the pump is existing gas can expand. But if no gas was
allowed to release any existing gas present, there will be hardly any leakage
continuously after fixed time intervals. If there despite the open valve because liquid cannot
is no gas, liquid will escape. Depending on the expand. After the next dosing stroke, the
pump capacity and amount of released gas, operating pressure is re-attained almost
the time interval can be increased or reduced. immediately and dosing is continued. It is an
This system also uses a non-return valve to advantage of this degassing device operated
ensure that the dosing line under pressure is by auxiliary energy that it can be controlled by
not depressurized during the degassing phase. an SPC (PLC). After longer standstill periods
The design has an optimized clearance on weekends, for example, a venting phase of
volume so that even small pumps re-attain full several minutes can be set, during which the
operating pressure right after venting and thus pump only recirculates the medium into the
continue to discharge without losses. chemical supply tank. The actual dosing
If the pump only carries out dosing strokes process can then be carried out without
after long time intervals and automatic venting disturbing venting phases.
Dosier-
Dosing
kontrolle
monitoring
Drain
Dränage
sleeve
Kabel
Cable
47
Sectional view of a backpressure and pressure relief valve (same fitting for both functions)
Kontermutter
Counternut
Federteller
Spring disk
Feder
Spring
Federgehäuse
Spring hou-
Klemmring
Clamping ring
Stützpilz
Support
Membrane
Diaphragm
Ventilgehäuse
Valve housing
a) Artificial backpressure
As mentioned before, the dosing capacity of 7bar. Backpressure valves work like an
diaphragm pumps depends on the overflow control and therefore do not allow
backpressure. If it can be anticipated that the pressures exceeding the aforementioned 7bar.
backpressure will fluctuate extremely (e.g. The pump must also attain this pressure if the
from 2 - 6 bar in a potable water line), an flow rate is reduced in order to push the
artificial backpressure which is always higher medium through the backpressure valve. In
than the maximum system pressure to be every case, the pump always has a constant
expected can be simulated for the dosing backpressure of 7bar and is not affected by the
pump by means of a backpressure valve. In fluctuating pressures between 2 and 6bar.
this particular case the valve should be set to
The flow rate is set without back pressure stroke length “b” must be adjusted to achieve
valve to 6bar and 100l/h as required via stroke 100l/h. Otherwise the flow rate would only be
length “a”. If the pressure goes down to 2bar, about 90l/h. With this constellation, the pump
the dosing pump will dose 110l/h and thus too will now continuously discharge 100l/h against
much. After installing the backpressure valve 7bar without noticing that the pressure is
and setting the opening pressure to 7bar, actually fluctuating.
48
l/h 2 bar
6 bar
7 bar
110
Dosing fluctuation
100 Sollwert
Set value
without backpressure
valve 90
0
a b Hubläng
Stroke length
Hub ohne
Stroke without Hubwith
Stroke
Druckhaltevent
backpressure valve
49
to various consumers
zu diversen Abnehmern
50
Fig 1: Direction A - B : keeping the pressure to approx. 3bar
Fig. 2: Direction B - C : pressure relief of the feed line for service purposes
Fig. 3: Direction B priming: anti-siphon effect = no siphoning
Fig. 4: Direction A - C : overflow = safety valve at approx. 11bar
Outlet
Austritt B Eintritt
Inlet B
Fig. 1 Fig. 2 Blowoff line
Abblaseleitung
C
Druckhalteventil
Backpressure Druckhalteventil Überströmventil
Relief valve
Backpressure
valve Flow
Durchflußindikator
valve
indicator
Eintritt
Inlet A
No
keinoutlet
Austritt B
Abblaseleitung
Blowoff line
Fig. 3 Fig. 4 Abblaseleitun
C
Überströmventil
Relief valve
Eintritt
Inlet A
51
Ball non-return valve Tubing non-return valve
Sitz
Seat
Kugel
Ball Ventilschlauch
Valve tubing
Spring
Feder
The principle of pulsation dampeners is that a cushion is separated from the medium by a
defined amount of gas is made available to the flexible elastomer wall (bubble, rolling
dosing system filled with incompressible liquid. diaphragm, tubing, etc.) The last version is to
The gas can be expanded or compressed be preferred because the dampening air does
close to the dosing pump by converting not get lost in the medium by absorption.
energy. It has the function of a gas spring. Depending on the installation and task,
There are two types of pulsation dampeners: pulsation dampeners can be used and are
those where the gas (air) is in direct contact necessary on the suction or discharge side or
with the medium and those where the gas on both sides at the same time.
52
1.3.10.1 Pulsation dampeners on the discharge side
The pressure pulsations caused by dosing dosing pump. For viscosities exceeding
pumps increase with longer dosing lines and 300mPa*s, no more than 1m/second has to be
smaller diameters and can result in taken into account with reference to uniform
inadmissible pressure peaks. Apart from non- flow. The aforementioned values are
uniform dosing undesired anyway, pressure recommendations to avoid gross errors. For
fluctuations are disadvantageous for the pump line lengths of 20 meters and more or
as well as for the piping. The velocity in the viscosities exceeding 1,000 mPa*s, the
piping should not exceed 1.5m/second on the pressure conditions for suction and discharge
discharge side, if the medium is similar to line as well as the perfect dosing behaviour of
water. As for a simple oscillating pump the the dosing pump must be verified using the
maximum output is three times higher than the standard calculation methods (see also
nominal capacity, three times the nominal chapters as of 1.3.1.1).
capacity must be taken into account when During the discharge stroke, pulsation
calculating the dosing line. Even if the dosing dampeners store a portion of the media dosed
line diameter is designed reasonably, it must and release it again during the suction stroke.
be checked for lengths exceeding 10m Thus the gap between the two dosing strokes
whether a pulsation dampener might be is filled. The following diagram for determining
required. Then three times the quantity the design of the pulsation dampener refers to
between dosing head and pulsation dampener a desired residual fluctuation around the
must still be considered. Only after the average discharge flow.
pulsation dampener must the line be
calculated with the single nominal value of the
Pulsation dampener without Pulsation dampener with
separation of medium and gas separation of medium and gas
Befüllstutzen
Filling sleevefürforLuft
airoder Stickstoff
or nitrogen
Compressed
komprimierte Luft air
Trenn-Membrane
Separating diaphragm
Medium (dringt
Medium fluktuierend
(fluctuating ein)
entry)
7
1 Tension cone
1 Spannkonus
2 Union nut
2 Überwurfmutter
3 Tubing
3 Schlauch
4 Charging valve
4 Befüllventil
5 Housing
5 Gehäuse
6 Support pipe
6 Stützrohr
7 Pressure gauge connection
7 Manometeranschluß
Schlauchkontraktionen
Tubing contractions
1 2 3 4 5 6
53
For perfect operation of the pulsation recharging that there is no system pressure on
dampener, it must be made sure that it is pre- the medium side during the gas filling process.
pressurized to 60 – 70% of the operating Therefore planning should include a pressure
pressure to be expected later on using relief valve. If this is not considered, the right
compressed air or nitrogen. IMPORTANT! gas pressure is reached but no or only
During the filling process, there must be no insufficient gas volume which is required to
pressure on the diaphragm side facing the allow the pulsation dampener to store a portion
medium so that the gas can fill the pulsation of the dosing stroke. Refer to flow diagrams
dampener optimally. Therefore it has to be 1.5.3.1.3.
ensured before startup or in the case of later
Residual fluctuation
Restschwankung
l/h
Zeit
Time
The following diagram refers to single-head of the later operating pressure, before the
dosing pumps with pulsation dampener, the pressure of the dosing chemical is applied to
total nominal volume V0 of which is the pulsation dampener.
prepressurized with air or nitrogen to 60...70%
+/-X%Druck-Schwankung
+/-X% pressure or dosing SizeGröße
of thedes Pulationsdämpfers
pulsation dampener Vo [cm3]
flowDosierstrom-Schwankung
bzw. fluctuations around the
average
um value
den Mittelwert 00
0 0 0 0 0 0 00 00
20 80 10 20 30 40 60 80 10 20 30 00
40
15
00
60
10
00
8 80
0
7 00
6 10
5
4
1
1 2 3 4 5 6 8 10 20 30 40 50 60 80 100 200 300 400 600 800 1000
cm3/Hub Hubvolumen
cm3/stroke stroke volume
54
Caution for automatic control systems:
According to the functional prinicple of a certain delay because a portion is first stored
pulsation dampeners, a portion of the medium in the pulsation dampener. The control
transported during the dosing stroke is stored behaviour of sensitive pH controls may thus be
in the pulsation dampener and released again affected.
during the suction stroke. Thus it may happen For dosing pumps which are used as
that, after the controller causes a dosing stop, correcting elements in automatic control
a small amount of medium continues to flow systems, this aspect should be taken into
and affects the controlled variable. If the account.
controller requires medium again, it flows with
Pulsation dampener
Pulsationsdämpf
55
1.3.11 Flow monitoring
There are many flow metering and monitoring devices on the market working according to the most
different principles:
The aforementioned and some other systems pump capacity is set using a bypass flow
are only insufficiently suitable for pulsating control valve and the set value is adjusted by
flow. Besides they cannot be used with a flow means of a tangent screw. With each dosing
rate below 50l/h at a reasonable price stroke, a float element must jump up to reach
compared to the other dosing units. Therefore the switch contact located at the set value
the FLOWCON system was developed adjusting screw. An electronic unit compares
especially for dosing pumps with their the command to initiate the dosing stroke with
pulsating output. It cannot directly measure but the switch contact of the flow sensor. As long
monitor the volume of each individual dosing as perfect dosing follows each trigger contact,
stroke. Failures or reduced flow rates per the dosing process continues without
dosing stroke are evaluated. interruption. The number of pulses accepted to
With the flow sensor FLOWCON, it is possible fail can be set at the electronic unit. If this
to monitor an accuracy of approx. 10% for number is reached, it releases an alarm and
dosing pumps with flow rates between 0.1l/h the pump can be switched off.
and 50l/h. The sensor is designed so that the
FLOWCON 2
1 Bypass valve
2 Contact adjusting screw
3 Float element with solenoid
4 Reed contact 3
4
56
Simple visual flow monitor
Inductive
induktiverapproximation sensor
Näherungssensor
Stray fieldwird
Streufeld is influenced
vom
by the eccentric
Exzenter beeinflußt
Schaltkasten
Switchbox
Tappet
Stößel
Rückholfeder
Return spring
57
Drain inlet
Metal pipe 1
Gap
Cable
Metal pipe 2
Drain outlet
The following main factors are essential for the selection of the pump:
Nature and properties of the medium
1. Concentration
2. Density
3. Temperature
4. Viscosity
5. Solidification temperature
6. Aggressiveness
7. Abrasiveness
8. Tendency to crystallize
9. Tendency to release gas
10. Toxicity (admissible threshold value)
11. Odor intensity
12. Steam pressure
13. Explosiveness (observe ex classification)
58
10. Length of the suction line (friction, cavitation, reduced output!)
11. Length of the discharge line (observe friction, acceleration pressure for backpressure)
12. Admissible flow rate fluctuations (e.g. with reference to flow meters)
13. Is pump to be installed in an ex area? (Motors, etc.!)
14. Indoor or outdoor installation (protective roof!)
For the versatile applications in process engineering, a large number of optimally adapted dosing
pumps was developed. The following diagram is meant to be a guide to select the right and most
economical dosing pump and to avoid design errors. With the diagram, preliminary decisions
considering the properties of the dosing chemical are taken, which must be taken into account when
finally determining the pump (e.g. that spring-loaded valves or wearproof packings are used).
Design aids
Before finally determining the dosing pump, the following questions must be answered:
1. Chemical
Which chemical is to be dosed and which are diaphragm dosing pump should be preferred
its properties? as far as it is possible with regard to pressure,
Is leakage admissable regarding toxicity, odor linearity, etc.
or aggressiveness? If not, the leakproof
a) Viscosity
The higher the viscosity, the lower should be suction and discharge valves is recommended
the stroke frequency or the larger should be for viscosities of 300mPa*s and more.
the line diameters. The use of spring-loaded
b) Abrasiveness
Suspensions (e.g. kieselguhr) or chemicals preferably if diaphragm pumps are not suitable
which tend to christallyze (phosphate solution) because of high pressure requirements. Highly
may cause premature packing leakage in the acid or alkaline chemicals, however, make the
case of piston pumps. Therefore piston pumps application of this type of packing impossible.
with Aramid-Kevlar packings must be used Then piston-diaphragm pumps must be used.
c) Aggressiveness
The materials of the parts in contact with the lists and then be determined depending on the
chemical should be preselected according to materials available for the pump.
practical experience and standard resistance
2. Flow rate
The dosing pump must be designed so that it perfectly. Diaphragm pumps are not suitable
achieves the maximally required flow rate at a satisfactorily at stroke lengths below 20%
setting of 80 – 90%. Thus there is still a against max. pressure. With lower pressures,
reserve and the accuracy of the pump is used the pump can still be used in this range.
59
3. Backpressure
Backpressure is important directly at the these conditions are not observed, the
pump. If the line from the pump to injection hydraulic system may be damaged or the
point is too long (e.g. more than 10m), output may be reduced. Use pulsation
pressure fluctuations may reach a dampeners to solve the problem.
considerable intensity and superimpose the Fluctuating backpressure may affect the
pressure at the injection point. With increasing accuracy of diaphragm dosing pumps. A
length, also the frictional losses are added to constant backpressure can be attained by
the operating pressure at the injection point. If using backpressure valves.
4. Suction pressure
The suction pressure of the running pump In the case of simple proportional dosing,
must not exceed the suction pressure however, this error might have a negative
admissible for the pump. In the case of effect. For piston and piston-diaphragm dosing
diaphragm dosing pumps, the suction pressure pumps, a fluctuating suction pressure is only of
must be kept as constant as possible, since minor influence. If extreme level fluctuations
fluctuating suction pressure also affects the are to be expected because of high supply
flow rate. tanks, a level-controlled intermediate container
A level varying by a head of 4 meters, for with float valve or a suction controller SDR can
example, would be extremely be used for the dosing pump.
disadvantageous, especially if in addition the Suction lines must be as short as possible or,
density was 1,900 kg/m³. The suction pressure for lengths of more than 8 meters, equipped
fluctuations of 0.76bar in this case would possibly with a pulsation dampener just before
cause dosing errors of much more than 10%. If the suction valve of the pump. In the case of
the dosing pump is operated as correcting closely dimensioned suction lines, a pulsation
element in an automatic control system, this dampener may already be necessary at a
effect would be of minor importance because a length of 3 meters.
controller would adjust the pump until the
required flow rate is achieved.
5. Dependence on pressure
Diaphragm dosing pumps are also dependent valve. It is set to a pressure which is approx.
on the backpressure due to the flexible dosing 1bar higher than the result of system pressure
diaphragm. The pump can be simulated a and line losses.
constant backpressure using a backpressure
In the case of automatic control systems (pH control), the non-linearity of a diaphragm is hardly of any
importance and would be compensated for by the controller.
60
Diagram for the selection of dosing pumps
no no no
no yes
yes yes no yes no
Diapragm Is Aramid
dosing Kevlar
pumps resistant to
the medium? no
or
yes
Then generally Piston-
all types of diaphragm Piston pump Piston pump
dosing pumps dosing pumps with Aramid with PTFE silk
can be used KMS packing packing
61
Nomogram to detrmine the pump size and running time per pulse
100 50 10 5 2 3 2 3 4 5 7 10 20 30 40 50 70 100
30 20
5,6 3,2
200
300
400
500
700
1000
1 2 3 4 5 6 8 10 20 30 40 50 60 80 100
Amount of 80
liters until 60
contact 50 Dosing chemical [l/h] for the
40 quantity of water to be treated
30
20
1
Example:
0.1 l chemical is to be used to treat each of 20m³/h water, i.e. 2l/h have to be dosed.
Question: Which must be the minimum size of the pump and how long must it run per water meter
contact which takes place every 50 l?
Solution: In the above nomogram, e.g. a pump is found which must run 5.6 seconds at a flow rate of
3.2l/h.
62
Nomogram to coordinate flow rate per cubic meter, water meter pulse sequence and solenoid
pump
10
7
5
4
3
ml/stroke of dosing pump
2
1000 ml/m3 100 ml/m3
0,7
0,5
0,4
0,3
0,2 10 ml/m3
0,1
0,07
0,05
0,04
0,03
0,02 1 ml/m3
0,01
0,1 0,2 0,3 0,5 0,7 1,0 2,0 3,0 5,0 7,0 10 20 30 50 70 100
l/Impuls
l/pulse des meter
of water
1.5 Installations
For selection of the dosing pump during The dosing pumps must not be installed in
planning and all the more for installation and rooms exposed to the danger of explosion
operation, the local rules regarding electrical unless they are marked with an appropriate
installation and handling of the chemicals must type approval label.
be observed. When working on suction and discharge lines
It is recommended to plan and install all of the pump or unscrewing connections or
additional fittings required to increase venting screws (e.g. on startup of the pump),
accuracy and operational reliability. These wear safety glasses and protective gloves, if
include relief valves used in the safety valve the dosing chemical is harmful to health. In the
function, backpressure valves to avoid case of chemicals releasing gas which is toxic
undesired siphoning and to improve dosing or caustic for the respiratory tracts, a breathing
accuracy, leakage probes for ruptured mask prescribed or recommended for the
diaphragms and low level indicators in the process must be used.
storage tank to prevent air from entering the Keep the operating instructions of the dosing
dosing head. pump and the relevant fittings readily
Disconnect the power supply and check that accessible.
there is actually is no voltage anymore before
working on the electrical wiring of the pump.
The power supply must be secured against
unintended reconnection.
63
Always use appropriate tools for the and prevent larger amounts of chemicals from
installation of plastic connecting parts. To escaping. Leakage due to diaphragm rupture
avoid damage, never apply excessive force. can be monitored automatically using a special
Plastic parts, especially PVC parts, can be fitting (leak check).
screwed and unscrewed more easily if the Both, the designer and the user are
thread is lubricated with vaseline or silicon responsible to make sure that the whole plant
grease before. including the dosing pump is designed so that
Caution! Check the compatibility with the neither plant equipment nor buildings can be
chemical to be dosed! For paint treatment severely damaged in the case of chemical
applications (e.g. spray booths), silicon must leakage caused inevitably by piston pumps or
not be used! by diaphragm rupture as well as burst tubing.
Never connect the pump to power supply, if no Dosing pumps are not responsible for
dosing lines are connected, since chemical unnecessary consequential damage. If there is
possibly existing in the head will spurt out to a high danger potential, the plant must be
the top. designed so that, even in the case of a pump
If connections at the dosing head must failure, no consequential damage appears
unscrewed for the purpose of venting or other which is unreasonably high compared to the
reasons, remove any leaking chemical, value of the pump. Leakage probes and
especially if it is caustic, aggressive or toxic, by containment tanks are therefore
all means and rinse it off with water, if recommended.
necessary. The manufacturer of the dosing equipment is
Dosing pumps are produced according to not responsible for damages due to excessive
highest quality standards and have a long or low flow rates resulting from wrong
service life. Nevertheless some parts are dimensioning, faulty pump settings or incorrect
subject to wear because of principle or insufficient installation of peripheral fittings.
(diaphragms, dosing valves, valve seats). To The following system flow diagrams are meant
ensure long operating life, visual checks are to be a planning aid for applications often
required from time to time. Particularly in the found in dosing technology.
case of diaphragm pumps, attention must be
paid to leakage at the fixing flange (drain
sleeve) to identify a diaphragm rupture in time
64
Protection against dry operation applies analogously for all following examples.
max. head
Float for
supply control
Foot valve with ball
check and filter
Head 1
At the same time the priming aid offers three more advantages:
1. Air and gas bubbles are collected for a long time instead of entering the dosing head.
2. The air chamber in the siphon-type collector acts like a pulsation dampener and ensures a
uniform supply from foot valve to collector.
3. The transparent design of the collector allows to check visually whether liquid is primed.
65
1.5.1.3 Suction line with pulsation dampener
If the dosing pump is positioned in the pulsation dampener is useful which is installed
geodetically admissible range above the level right before the suction valve.
but at a lateral distance of e.g. more than 5m, If long suction lines cannot be avoided, check
the pressure may fall below the steam the acceleration pressure and dimension the
pressure of the liquid (cavitation) due to the cross section of the suction line sufficiently in
acceleration pressures. A reduced output or the course of planning.
dosing failure may be the result. In this case a
Pulsationsdämpfer
Pulsation dampener
IfBei dersuction
long Planunglines
muß bei nicht vermeidbaren
cannot be avoided,langen
checkSaugleitungen
the acceleration
der Beschleunigungsdruck
pressure and dimensionüberprüft undsection
the cross der Saugleitungsquerschnitt
of the suction line
ausreichendinbemessen
sufficiently werden.
the course of planning.
Saugleitung möglichst kurz
Shortest possible length and
oder
largestaber groß im diameter
possible Durchmesser,
of
wenn auf Pulsationsdämpfer
suction line, if no pulsation
verzichtet werden
dampener soll.
is used.
1.5.2 Installation of the dosing pump on the side of or below the chemical tank
1.5.2.1 Connection at the bottom of the tank
1.5.2.1.1 Standard installation
If the level has changed by more than 1m, it used as an alternative. The negative influence
must be checked, whether the varying supply of the varying supply pressure can also be
pressure affects the accuracy of the eliminated by installing a suction controller
diaphragm dosing pump, taking the density SDR or an intermediate container with
into account. If this is the case, piston pumps constant filling level.
or piston-diaphragm pumps can possibly be
Saugleitung
Keep suctionkurz
line oder
shortaber großinimdiameter,
but large Durchmesser halten,
AbsperrventilSchmutzfilter
Shutoff valve Dirt filter sonst Pulsationsdämpfer
otherwise mount pulsationkurz vor dem
dampener Saugventil
right montieren.
before suction valve.
66
1.5.2.1.2 Suction line installation for effervescent media
To avoid that more gas than inevitable reaches suction line to keep the flow velocity low. If the
the dosing head, the suction line should be problem of released gas cannot be solved
connected to the suction valve with a positive differently, the gas collector described under
suction head so that the gas flows back to the 1.5.2.1.2.1 or the head venting equipment
tank. This also requires an overdimensioned treated under 1.3.5 must be used.
Gas
Dosing Dosiermittel
chemical
1.5.2.1.2.1 Gas collector instead of the inclined suction line right before
Also a gas collector, which besides has the the suction valve. It must, however, be vented
positive effect of a pulsation dampener on the from time to time, i.e.: be refilled with medium.
suction side, can be installed in addition to or
67
Level
Niveau
variable
veränderlich
Niveau
Level
konstant
constant
.
1.5.2.2 Installation of the dosing pump for those applications which, for safety reasons, do not
allow to connect the tank laterally or at the bottom (prevention of water pollution).
Supply is only permitted from the top.
1.5.2.2.1 Standard installation
HeadHöhe
FootFußventil
valve withmit Schutzsieb
protective filter
Pulsation dampener
Pulsationsdämpfer
empfohlen
recommended
Ventil for
Valve zurdismounting
Demontage the
der pump
Pumpe
This installation is only functioning if the head suction line length is counted from the foot
H to be overcome at minimum level can also valve for the liquid head to be accelerated and
be achieved by the still dry pump, taking the can cause priming problems due to the long
density into account. If the lines are filled, the line. A pulsation dampener as described under
hydrostatic pressures in the lines inside and 1.5.1.3 is helpful, because the pressure peaks
outside the tank neutralize each other so that produced by acceleration are reduced.
this system behaves statically like the system For effervescent media a siphoning system as
according to fig. 1.5.2.1.1. An important described under 1.3.3.2 can be used.
difference, however, has to be considered: The
.
68
Filling funnel for suction line
Füllstutzen für Saugleitung
Close
Ventil valve
nach tightly dicht
Befüllung after absperren
filling
Head
Höhe
Volume Vs
Höhe of the
Head
suction line
1.5.2.2.4 Suction line with overflow container to keep the supply head constant
The flow rate of diaphragm dosing pumps more than maximally primed by the dosing
depends on the suction or supply pressure. pump. The quantity not required by the dosing
This influence can be eliminated by means of pump is returned to the supply tank.
an overflow container constantly filled to the The filling pump does not have to be a dosing
same level. Just a separate filling pump might pump.
be necessary which permanently delivers
69
Overflow container
Überlaufbehälter
1.5.3.1.3 For line lengths of more than 10 m, the extent of the pressure peaks caused by the
oscillating operating mode of the dosing pumps must be checked.
To reduce the pressure peaks, either the line dampener can be locked and relieved by
diameter must be increased or a pulsation means of valves from operating pressure for
dampener used. If a pulsation dampener is later maintenance and refilling of gas.
installed, it must be ensured that the
V1
Filling valve
Befüllventil Filling valve
Befüllventil
V2
V1
V2
Anschluß über
Connection via T-Stück
T-piece Anschluß im Durchfluß
Connection (Inline)
inline with flow
Before each check or refilling of air, the the system under pressure by shutoff valve V1
pulsation dampener must be separated from and relieved by valve V2
70
1.5.3.1.4 Suspensions
Suspensions tend to deposit also in functional the discharge valve and affect the restart.
parts of the pump such as valves. During Therefore it is recommended to shift the line
standstill periods the particles would “cement“ laterally directly above the valve.
Partikel lagern
Particles deposit on
sich in
aufthe
undvalve Particles deposit only
Partikel lagern
and
im Ventil ab insich
thenur
bend and can
beim washed
Knick ab away
Malfunction on
Funktionsstörung und können
bei Inbetriebnahme
startup fortgeschwemmt werden
bad ! !
schlecht better
besser !
1.5.3.1.5 Flushing
In addition to the previous chapter, flushing of using a a time relay. If the flushing water (e.g.
the complete dosing head is recommended at in the case of settling basins) can also be
certain time intervals and/or standstill periods. routed to the dosing point, 2 valves (and D)
This task can be controlled by the process flow can be saved.
zu = closed
D zu
auf = open
A auf
B auf B auf
C zu C zu
71
falsch
wrong
Überströmventil
Relief valve / bzw.
Sicherheitsventil
safety valve
richtig
right
72
Gradient
Gefälle
Backpressure valve
and
antisiphon valve
7
5
8 5
4 4
12 8
9 6 6
3 3
2 2
1 1
73
1.5.3.4 Piping nomogram
d (mm) w (m/s)
100 Q (l/h) * 10
90 9 * Bei oszillierenden
*For Dosierpumpen
oscillating dosing pumps, the nominal
8 istpump
vor Ermittlung
capacityder Nennweite
must be multiplied by three
80 7 diebefore
Pumpen-Nennleistung mit 3 zu width, if no
calculating the nominal
100.000 6 multiplizieren, wenn keinis used.
pulsation dampener
70 5 Pulsationsdämpfer eingesetzt wird.
50.000 4
60
30.000
3
50 20.000
Recommended
empfohlene flow velocity liquids für
Strömungsgeschwindigkeit similar
2 wasserähnliche Flüssigkeiten auf der
to water on the
10.000
40
5.000 discharge der
Druckseite sidePumpe
of the pump
3.000 1
30 0.9
2.000 0.8
0.7 suction side of the pump
1.000 0.6 Saugseite der Pumpe
0.5
20 500 0.4
Caution!
300 Achtung!
0.3 For
Bei line lengths exceeding
Leitungslängen über 2m on the
200 2msuction
auf derside and 10m
Saugseite undon the discharge side
15 as auf
10m wellder
as Druckseite
viscosities of more than 20mPa*s
0.2 pulsation
sowie dampeners
Viskositäten or a further reduction
über 20mPa*s
100 werden
of thePulsationsdämpfer oder weitere
flow velocity are recommended.
Reduzierung der doubt,
If there is any Strömungsgeschwindigkeit
recalculate the
50 empfohlen.
pressure loss of the piping using the
Im Zweifel Druckverluste der Rohrleitung
10 30 0.1 mitformulas foundder
den Formeln in Fachliteratur
technical literature or
0.09 chapter
oder Kapitel1.3.1.1.
1.3.1.1 nachrechnen.
9 20 0.08
0.07
8 10 0.06
7 0.05
5 0.04 Example
6 Beispiel
Dosing pump GMR 2000
3 Dosierpumpe GMR2000
0.03 Without
Ohne pulsation dampener,
Pulsationsdämpfer sind
2 2000l/h*3
5 2000l/h*3 zumust be considered
berücksichtigen
1 0.02 6000l/h
6000l/hbeiat1m/s
1m/sergeben 45mmto 45 mm.
correspond
4 DN50
DN50 istmust
zu wählen, wenn die
be selected, if the
vorstehenden
aforementionedPunkte beachtet
points werden.
are observed.
0.5
0.3 0.01
3 0.009
0.2 0.008
0.007
0.1 0.006
0.005
2 0.05 0.004
0.03
0.003
0.02
1.5
0.01 0.002
0.005
1 0.003 0.001
74
1.6 Accuracy of dosing pumps
Dosing pumps do not principally have a system already, appropriate precautions must
specific accuracy. Their precision also be taken to produce stability or at least
depends on adherence to the operating mode minimize variation.
of the pump. Therefore it is very important that For the pump itself, the achievable accuracy is
the operating data given during setting of the already defined during construction. Design
required flow rate are kept to all the time. Only and dimensional stability of the machine parts
then can a sufficiently constant dosing be against application of force and compressive
ensured. The operating conditions include the stress as well as backlash-free concurrence of
characteristic of the medium, its temperature the moving elements are the preconditions.
and viscosity, supply pressure or suction Constant backpressure can be produced by
pressure as well as backpressure. Of course, using backpressure valves, constant suction
such parameters as voltage and mains pressure conditions are achieved by means of
frequency which have an effect on the drive a suction controller or level-controlled
motor are also important. In the case of intermediate containers.
diaphragm pumps, it must be additionally If all aforementioned parameters are constant,
considered that rigidness decreases in the the output can be evaluated according to the
course of service time. If the constancy of the following criteria:
aforementioned data is not provided by the
As the parameters contained in the equation output of 25%. Then ± 1 l/h already
are not constant in practice but are subject to corresponds to ± 4 % related to 25 l/h.
production faults, pressure and temperature Such errors relative to the maximum value are
influences as well as fluctuations of the mains e.g. leakage at the piston or slip of leaking
frequency and voltage in the case of three- valves.
phase motors, the output achieved is not Other errors refer to the individually set output.
100% but just a certain portion of it. This is Then an error of ± 1 % corresponds to only
expressed by efficiency ε which itself is not 0.25 l/h, if the 100 l/h pump is set to 25%. A
constant either but depends on the pressure fluctuating mains frequency is such an error,
especially if strain or gas enclosures occur. for example. A change in speed of ± 1 %
ε can be determined by trials. influences the 100l/h setting and the 25l/h
There are errors which are constant in setting by the same percentage, i.e.: ± 1l/h at
absolute values for all stroke settings and 100 l/h and ± 0.25 l/h at 25 l/h output.
therefore affect the output more strongly in the Errors caused by strained diaphragms and by
case of low stroke settings. An error of ± 1 % compression or expansion of air and gas
corresponds to ± 1 l/h for a 100 l/h pump. This enclosures in the pump head are most difficult
error also occurs, if the pump is set to an to control.
75
Therefore the design engineer should reach an accuracy of approx. 3% related to a
minimize clearance volumes and elastically stroke length of 100% at constant operating
compressible parts and the planner should conditions. Contrary to piston dosing pumps,
design the installation so that no gas enters however, the influence of the share of error
the dosing head. caused by the strain of the diaphragm is strong
The dosing accuracy can be increased right and grows superproportionally at low stroke
from the beginning if the user does not only lengths. Therefore diaphragm dosing pumps
refer to the adjustment scale of the dosing should not be operated at stroke lengths below
pump and characteristic curves of the data 20%. At a stroke length of 20%, the dosing
sheets but calibrates the dosing pump under error may already be higher than 10% of the
operating conditions (see chapter 1.7). values stated according to the characteristic
For piston dosing pumps, a dosing accuracy of curve. The accuracy of the dosing pumps is
0.5…1.0% at constant operating conditions almost unimportant if they are just used as
can be stated. This accuracy is achievable by conveying (feed) pumps or as correcting
an adjusting range of 10…100%. At a stroke elements in automatic control systems. In the
length below 10%, the error increases latter case, the controller adjusts the pump
superproportionally. Diaphragm dosing pumps until the set process value is reached.
% Dosierfehler bezogen
Dosing error auf die
related todosierte Menge
the dosed quantity Dosing error
% Dosierfehler related
bezogen todosierte
auf die the dosed quantity
Menge
6 6
5 5
4 4
3 3
2 2
1 1
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
% Hublänge % Hublänge
% stroke length % stroke length
76
valve (5) must be closed. Then the pump measuring vessel (11). After one minute has
discharges through the backpressure valve (7) passed, the relay switches the solenoid valve
and builds up the required pressure. The test (9) back to outlet (A). The dosed quantity (11)
pressure is to be read at the pressure gauge is recorded and compared with the calibration
(6), not at the pulsation dampener (4). curves of the pump.
According to its setting, the pump discharges For solenoid dosing pumps, it is more
the quantity to be tested against the pressure important to know the quantity dosed per
read at the pressure gauge (6) via the solenoid stroke. Therefore the time relay (9) is replaced
valve (8) to outlet (A) and back into the supply by a counter. After activating the counter, the
tank (12). From this uniform operation, the pump then discharges for the duration of e.g.
dosing output is now measured for e.g. 1 100 strokes into the tank (11). In this
minute. This is possible by activating a time connection, the time needed to carry out the
relay (9) with the help of a key button (10) 100 strokes is less significant. Nevertheless it
which switches the solenoid valve (9) for is recommended to complete calibration at
exactly one minute to route the dosing quantity approx. 80% of the maximum stroke
from the connection piece (B) into the frequency.
5
B 2
A
1
11
12
77
Installation diagram and calibration during operation
C
A B
Positions of
Stellungen desthe three-way valve
3-Wege-Ventils
C C C C
A B A B A B A B
Filling
Füllungofdes
the Pump
Pumpeworks under operating
unter Betriebsbedingungen Umschalten
Switch overund
and nach einer
Switch over Minute wieder
again to supply
Meßglases glass
measuring conditions until bis
arbeiten lassen, operating
Betriesdruck gleichzeitig
stop Zeit stoppen
simultaneously auftank
from Entnahme aus Behälter
after one minute and
pressure is constant
konstant ist umschalten und Meßglas ablesen
read measuring glass
1.8 Maintenance of dosing systems
The importance of the system and its danger aforementioned influences. A general rule for
potential for human being and equipment in important industrial processes could be that
the case of malfunction determines the the diaphragm is replaced preventively once a
frequency of maintenance or precautionary year. The pump system should be checked for
inspection of dosing systems. As pumps and leakage at least once every week. To avoid
their fittings for dosing more or less aggressive damages occurring between the inspection
chemicals are also potential sources of times, the installation of containment tanks
danger, these must be planned and installed around the pump and/or leakage probes is
appropriately. It is not possible to clearly define recommended as mentioned before.
possible failures to be expected, since dosing For many applications, local rules or
pumps – just like other technical devices – are regulations for prevention of accidents apply.
also subject to wear, which mainly depends on Some applications allow the installation of the
whether the system is working 24 hours per chemical tank only in containment tanks
day or just sporadically and whether the anyway. The pump should also be mounted at
devices operate at their nominal capacity limit this area. It is recommended, in some system
or are only utilized partly. Especially areas prescribed, to route the lines through
diaphragms of dosing pumps are not onIy jacket tubes to be able to collect any leakage
affected by the service life but also by caused by bursting pipes.
chemical corrosion and furthermore by If the standard process-related and legal rules
weakening due to ageing unavoidable in the as well as the maintenance instructions for
case of elastomers. From experience, the life dosing systems are observed, the risk of
of diaphragms is therefore between 1,000 and damage is extremely low.
20,000 hours, depending on the
29.06.1999
Günther Bolte
78
pumps
Centrifugal
technology
control
and
Measuring
Chlorination
feeder
Dry
pumps
Dosing