Innovations in Diaphragm Metering Pump Technology Enhance Performance

Diaphragm pump technology has been in use for decades and these pumps remain a popular choice for chemical metering. Many industries — including water and wastewater treatment — rely on this technology because it is affordable and also familiar, which provides a high degree of operator comfort. Diaphragm pumps are typically simple to use, and most are rated for use with the high-pressures that are common in many applications.

Despite these advantages, traditional diaphragm pumps can be problematic. Operators often struggle with inconsistent performance, including issues like pulsation, unexpected flow rate variation, vapor locking, diaphragm wear, leaks, and overall high maintenance. However, there are recent innovations in diaphragm pump design that eliminate these issues.

Advanced technologies are making diaphragm metering pumps more reliable, eliminating age-old issues and significantly cutting down on both regular and unexpected maintenance.

Challenges with Traditional Diaphragm Pumps

One of the most common sources of frustration for traditional diaphragm pumps is vapor locking. This can happen when the pump is surging too fast or not completing a full stroke, which ends up agitating the chemical being dosed into a gas. Other times it occurs when the pump is running too slowly. Highly sensitive chemicals, such as peracetic acid (PAA), can trigger vapor lock almost immediately, regardless of what is happening with the pump.

Leaks and material failure can be chronic issues. The chemicals being metered can be abrasive, which may damage the diaphragm and weaken seals. When this happens, leaks often occur. Operators must then either replace the diaphragm and/or re-torque the screws and change out adapter O-ring seals resulting in added maintenance, effort, and downtime for the operator.

Innovations In Performance: Dual Diaphragm Hyperdrive Technology

Recent technological advancements address these age-old issues, resulting in a more reliable diaphragm pump that is essentially plug-and-play. The core innovation is dual-diaphragm Hyper- Drive technology. This innovative technology operates so that when one diaphragm is in the suction phase of the pumping action, the other one is in the discharge phase. This results in smooth, consistent dosing regardless of motor speed. The pump delivers even and near-continuous chemical dosing which prevents chemical agitation, allows the pump to run at an extremely low turn down, and effectively mitigates issues with vapor lock.

Blue-White Industries developed Hyper-Drive technology which is incorporated in the company’s Advanced Performance CHEM-FEED® MD1 Diaphragm Metering Pump (Figure 1). MD1 is also equipped with a brushless direct current (BLDC) motor. Accurate dosing relies on precise control of motor speed and torque. In a BLDC motor there is a direct relationship between the voltage applied and the rotor’s position, which allows for the tightest control over rotational speed. BLDC motors provide continuous, non-interruptive rotation. These factors ensure a smooth, steady flow of fluid, enabling consistent chemical delivery throughout the entire dosing cycle. The BLDC motor also reduces energy consumption and provides long-lasting durability in harsh environments.

Material And Design Enhancements

Hyper-Drive technology is an integral component of the Enhanced CHEM-FEED® MD1 dual diaphragm pump. The MD1 also incorporates a number of other design innovations that reduce maintenance, increase the pump’s lifespan, and reduce downtime and operator frustration. These include:

• DiaFlex® Diaphragm. Manufactured in-house from patented material, DiaFlex® Diaphragms have the rigidity necessary to withstand a wide range of abrasive chemicals, as well as the flexibility required to operate as a diaphragm. DiaFlex® has been tested to and is warranted to last the life of the pump, meaning operators won’t have to worry about changing out the diaphragm regularly thus reducing both downtime and expense.
• One-way Cartridge Valves. The MD1 is equipped with mistake-proof one-way check valves that are engineered so the user can only install them in one direction. This prevents the potentially dangerous issue of check valves being installed incorrectly, which can lead to leaks or even cause piping to rupture
• Improved Diaphragm Sealing. Six equally spaced mounting screws now secure the pump head diaphragm, replacing the previous four-screw configuration. This provides improved sealing and pressure distribution. Screws no longer interfere with the diaphragm, preventing leaks and enhancing seal integrity.

Additional MD1 enhancements include:

• Re-engineered Pump head Mount. Larger and More Robust. The pump head mount has been slightly enlarged and reinforced to minimize flexing relative to the drive enclosure. This allows for more consistent flow rates and performance.
• Upgraded Center Bearing. A significantly larger center bearing provides better support for the motor driveshaft, reducing lateral movement and increasing overall durability. This increases durability of the pump and minimizes shaft deflection and wear.
• Performance & Efficiency. MD1 delivers up to 7.0 GPH at 180 PSI. This level of performance covers demanding municipal and industrial applications.
• Keep it Simple. I/O connections are made easy with M12 connectors, no more complex wiring. USB-C connector allows for easy firmware updates in the field.

Technical Overview

• Output range: 0.0007–7 GPH
• Suction lift: 20 ft.
• Pressures: Up to 180 PSI (12.4 bar)
• Motor: Brushless DC
• Turndown ratio: 10,000:1
• Warranty: 5 Years
• Standards: NEMA 4X (IP66), NSF/ANSI 61, CE, cETLus