Troubleshooting Series: Diaphragm Failure on Air-Operated Diaphragm Pump

Troubleshooting Series: Possible Scenarios When the Diaphragm of an Air-Operated Diaphragm Pump is Damaged

1.Abnormal Frequency: When the diaphragm is ruptured, air pressure may leak from the rupture point, preventing the diaphragm from pressurizing properly. This disruption affects the pressurization schedule, leading to irregular and abnormal pump operation frequencies. In severe cases, a ruptured diaphragm can prevent pressurization altogether, causing the pump to stop functioning.

2.Liquid Leakage from Exhaust Port (Silencer): Diaphragm rupture can result in the transported liquid seeping into the air chamber through the rupture hole and subsequently being discharged from the exhaust port (silencer). If the transported liquid tends to solidify, it can lead to air chamber blockages, resulting in pump failure. Additionally, it is essential to consider and eliminate the possibility of condensation in the compressed air lines.

3. Entrapped Gas in Output Fluid Piping: Diaphragm rupture may cause gas to leak from the rupture hole into the fluid transport piping during pressurization. This leads to a mixture of liquid and leaked gas in the piping, which can also impact the quality of the liquid being transported. Furthermore, it is important to ensure proper sealing at the junctions during piping assembly to prevent air from being drawn into the pump's fluid piping through gaps.

Troubleshooting Series: Analysis of the Causes of Diaphragm Rupture in Air-Operated Diaphragm Pumps

When you notice "fluid leakage from the exhaust port" or "air entrainment in the pump's discharge piping" in an air-operated double diaphragm pump, diaphragm rupture can occur due to various reasons. Here are the possible causes:

🔸Excessive Pressure: Incorrect operating conditions, such as high pressure or excessive flow rates, can stress the diaphragm excessively, leading to rupture. Ensure that operations stay within design specifications and adjust air pressure and flow as necessary.

🔸High Fluid Temperature: Elevated temperatures of certain fluids can damage the diaphragm, making it brittle and prone to rupture. Ensure that the pump materials and diaphragm material are suitable for the temperature conditions.

🔸Corrosive Fluids: Passing inappropriate fluids or chemicals through an air-operated double diaphragm pump can lead to diaphragm rupture. Some fluids may corrode or erode diaphragm materials, making them brittle and eventually causing rupture. Therefore, selecting appropriate materials is crucial when handling specific fluids. You can refer to "Chemical Compatibility Chart" to understand suitable diaphragm materials for the transported fluid.

🔸Presence of Solid Particles: If hard solid particles are present in the fluid, they can get lodged between the diaphragms or puncture the diaphragm during operation, causing damage and rupture.

🔸Improper Diaphragm Storage: Diaphragms should be stored in a cool, shaded area to prevent exposure to direct sunlight. Prolonged exposure to sunlight can make diaphragms brittle and prone to rupture. It's best to wrap them in newspaper or opaque packaging and store them in a shaded location.

🔸Incorrect Installation or Maintenance: Incorrect pump installation or errors during maintenance, such as overtightening bolts or improper diaphragm cleaning, can damage the diaphragm.

🔸Unstable Air Supply: Unstable air pressure supply or pressure fluctuations can subject the diaphragm to excessive stress, leading to rupture. It is advisable to use a stable compressed air supply and monitor air pressure.

🔸Aging and Wear: Diaphragms are consumable parts, and with time and usage, their performance degrades. Prolonged use can make them brittle, eventually leading to rupture. Regularly inspecting and replacing aging diaphragms is key to preventing rupture.

By addressing these potential causes and adopting proper maintenance practices, you can help extend the lifespan of the diaphragm in your air-operated double diaphragm pump, ensuring reliable and safe operation over an extended period.

Troubleshooting Series: How to Extend the Diaphragm's Lifespan in an Air-Operated Diaphragm Pump

Regular Cleaning and Maintenance of Pump Fluid Space: It is recommended to empty the pump's fluid chamber and piping of liquid after each use. Then, circulate a suitable solvent to clean the chamber and piping to keep them clean. This helps prevent the possibility of diaphragm deformation or rupture due to the solidification or sedimentation of fluid in the chamber.

Filter Out Inappropriate Large or Sharp Particles: If the transported fluid contains impurities or particles, it is strongly advised to install appropriate filtration devices to prevent the entry of oversized or sharp objects. This helps avoid the possibility of diaphragm deformation or puncture and also prevents damage or blockage of piping or valve components.

Choose Diaphragm Material Suitable for Fluid Characteristics: When selecting the specifications of the pump, consider the chemical nature, temperature, impurities, and other characteristics of the fluid being transported. Therefore, before purchasing, confirm whether the selected diaphragm material is suitable for the transported fluid to avoid diaphragm damage, pump failure, and additional maintenance costs due to an unsuitable diaphragm material.

Maintain the Correct Operating Pressure Range: Air-operated diaphragm pumps have a specified operating pressure range, which can be found in the catalog or detailed instructions. When operating the pump, ensure that the input air pressure falls within the designated working pressure range to avoid excessive pressure that could cause diaphragm deformation or damage during fluid pressurization.

Diaphragm Storage: Diaphragm materials are typically plastic or rubber, so avoid exposure to sunlight and air during long-term storage. When these materials undergo photooxidation or thermal oxidation reactions, their molecular chains or chemical structures can change, resulting in brittleness, hardening, deterioration, or loss of elasticity. This can affect the diaphragm's lifespan and performance.

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2023-10-25