Feature Report

A Primer on

Reciprocating Metering
Pump Technologies
Understanding what technology is available is a first step towards selecting the right pump for
metering applications

Nils Kohlhase
University for Applied
Science in Lubeck
i.j •!
Fluid

I l_J
IN BRIEF
:n NSSS BASIC CONSTRUCTIONS

Pump head | Pumph DRIVE ELEMENTS

PUMP HEADS

eciprocating metering pumps are FIGURE 1. These diagrams show the principle designs of a CONDITION MONITORING

R
piston pump (left) and a diaphragm pump (right)
problem solvers for difficult fluid­
OUTLOOk
handling tasks and applications.
Their main function is the meter­ ing of the fluid. For most of the pumps, the
ing of a precise fluid volume per stroke stroke length can be adjusted for different
in a specified period of time. For this, the flowrates. Due to this, reciprocating pumps
accuracy of the metering flow is the criti­ have the following three characteristic prop­
cal, value-added element of these pumps. erties (Figure 2):
They are used in different industries, such • The flowrate is extraordinarily independent
as the chemical, oil-and-gas and pharma­ of the discharge pressure, in comparison
ceutical industries for applications with to other types of pumps
partially specific properties. While operat­ • A digital character of the flowrate over time
ing pressures can range from atmospheric • A linear dependence of the metering flow
pressure to 3,500 bars, the properties of on stroke length and stroke frequency
the fluids can be extreme. Examples are
applications with very low or high tempera­ Drive elements
ture, very high or low viscosity, thixotropic Many different drive designs are available on
fluid behavior, shear sensitivity, abrasive­ the market today. Important requirements for
ness due to solid contents, toxic or cor­ these drive elements are as follows [?]:
rosive behavior. • Rugged design, capable of sustaining
overload
Basic constructions • Adjustable stroke length
The pumps consist of two main elements: • Linearity between stroke adjustment and
the drive element and the pump head, as stroke length
shown in Figure 1. The drive element con­ • Harmonic reciprocation motion with con­
verts the electrical energy into the recipro­ tinuous plunger viscosity curve over the
cating movement of the plunger while the stroke length
main task of the pump head is the meter- • Constant front dead point, independent of

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2019 43

 Reciprocating positive
displacement pump

Rotary positive
displacement pump
Flowrate, V

Flowrate, V

Flowrate. V
centrifugal pump

Pressure, p
1I1 Time, t
Stroke frequency, stroke length, n

FIGURE 2. These grap ihs show stroke-length setting tering racy at partial stroke length,
the main characteristi cs of re-
ciprocating diaphragn l pumps
The last two requirements are prerequi­ Figure 3 sh ows five different principle de-
sites for an optimum pump-head opera­ signs and tt leir properties.
tion. A discontinuous viscosity curve can The cam drive concept (Figure 3C) is an
lead to hydraulic pressure shocks. And a interesting s solution for small- and mid-size
FIGURE 3. Different c
for drive elements are pre-
constant front dead point is important to discharge p owers. It has a constant front
seated here reduce the pump head efficiency and me­ dead point, which is the precondition for
small pump-head dead
DIFFERENT CONCEPTS FOR DR VE ELEMENTS spaces, and linearity be­
Drive Mechanical Example Properties tween stroke adjustment
stroke ad­ and stroke length. This
justment guarantees a very precise
Solenoid drive adjustment. The main dis­
•Economic solution for small power advantage of the cam drive
• Direct conversion into reciprocating movement
concept is the shock-like
Solenoid

with integrated stroke adjustment

•Linear stroke adjustment kinematics in partial stroke
• No harmonic reciprocation motion range. Depending on the
•Constant front dead point
adjusted stroke length,
the adjustment screw
Straight crank drive blocks the movement of
Jr,*:-
• Rugged design possible the plunger abruptly in the
• No stroke adjustment Nearly harmonic oscillating
i suction stroke. This leads
movement
to mechanical and hydrau­
No
lic pressure shocks. With
small pumps, these shocks
can be acceptable, but for
larger discharge powers,
u era move m i Cam drive cam drives are not optimal.
•Economic solution tor small and mid-sized power A good compromise for
-JLfi •Linear stroke adjustment
•At partial stroke length no harmonic reciprocation
mid-size to high-hydraulic
motion power is the crank drive with
•Constant front dead point variable eccentricity prin­
Revolving crank mechanism ciple (Figure 3E). As shown
■ ii Stroke length • Rugged design possible in the right-hand side of Fig­
DisctijnJe* ^rt Q 1 •Very often no linear stroke adjustment
•Nearly harmonic reciprocation motion
ure 3E, a mechanism con­
Cross head
/ f worm gear Suctwn •Constant front dead point possible verts the axial movement of
Rotating crank
the wedge (1) into a radial
Yes movement of the eccentric
Crank drive with variable eccentricity disk (2) for the adjustment
• Rugged design possible
of the stroke length of the
•Linear stroke adjustment
• Nearly harmonic reciprocation motion
crank. Due to the crank
• No constant front dead point drive, the center point of the
movement at partial stroke
fed is constant. Thus, the front
o* dead point varies at partial
u stroke length. This is the
only disadvantage of this
drive principle.

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2019

 R#3

Plunger

'XVV
• >>-VY
Diaphragm

H i l l
■

FIGURE 4. Plunger pumps can be equipped with FIGURE 5. In mechanically coupled diaphragm pumps, the diaphragm is directly assembled to the
sterile interfaces with flushing provisions (a) and plunger. The diaphragm has to seal and to convey against the operating pressure. Therefore, such pumps
different systems for the flushing of seals (b) to are suitable for low-pressure applications and smaller flowrates
separate particles from seals

In recent years, new drive ele­
ments with integrated servo drives
have been developed. One supplier,
for example, has used the existing
mechanics of the drive elements
[12). In the automotive industry,
servo-driven piston pumps are used
to apply adhesive [74]. These me­
ters use roller screw drives for the
conversion into a reciprocating
movement. This is possible because
the stroke frequency is very low with
one stroke per minute. Both solu­
tions can generate the partial stroke
by controlling the movement of the
servo drive. They allow individual
suction and discharge stroke char­
acteristics for high-viscosity fluids,
easy data communication with other
systems and easy integration into
process control systems. It is to be
expected that more drive elements
with servo drives will be required in
the future.
Pump heads temperature up to 400°C. For ex­
Pump heads can be classified as cluding contamination or infec­
either plunger- or diaphragm-type tion entering from the outside, for
pump heads. example, in the pharmaceutical
Plunger pump heads. Plunger industry, sterilizing flushing of the
pump heads are comparable eco­ seals (with wet steam, for exam­
nomic solutions for metering ap­ ple) creates safely operating ster­
plications when leak-free solutions ile interfaces, as shown in Figure
are not required. They are suitable 4. Especially for suspensions, the
for extreme operating conditions like sealant can be protected by forced
very high or low temperature or the flushing of a front-side sealing gap
highest pressures. into the working chamber. Various
The sealing concept is very im­ configurations have been applied
portant for this type of pump head. successfully for this purpose (3).
All efforts to improve the operational Diaphragm pump heads. The main
response of seals cannot overcome advantage of diaphragm metering
the fact that leakage flows are un­ pumps against plunger pumps is the
avoidable in dynamically operating hermetically sealed tightness of the
seals. Often, small flows are even pump head. Instead of a dynamic
functionally necessary for lubrica­ sealant, the pump head is equipped
tion. Most of the sealing solutions with a diaphragm that serves as a
have been proven for years. Stan­ flexible, static seal. Therefore, these
dard sealing solutions are single- or pump heads are compatible with dif-
double-tensioned gland packing ficult-to-handle fluids, such as toxic,
for pressure up to 500 bars and flammable and corrosive fluids, as

, Perforated disk

discharge valve opens discharge valve closes

Plunger

pn*4
Diaphragm
conveying

Replenishing
valve opens

v, +
V,
§§IsSsI
Pressure, barg

decompression WIBW HI

Replemsbing valve

20
FIGURE 6. (Above) In a hydraulically coupled diaphragm-pump head, suction process
the diaphragm separates the pressure chamber Into an operating o
suction valves
chamber and a hydraulic chamber opens doses * I
FIGURE 7. (Right) This graph shows the pressure behavior of a dia- -20
phragm pump versus time 0.2 0.4 0.6 0.8 1 1.2 1.4
I Time, s

CHEMICAL ENGINEERING WVWV.CHEMENGONLINE.COM SEPTEMBER 2019 45

FIGURE 8. This patented high-pressure dia­ lically coupled diaphragm pump is
phragm-pump head prevents damage to the dia­ Integrated safety and
replenishing valve
shown in Figure 6. The diaphragm
phragm during startup
separates the pressure chamber
P non into an operating chamber and a
hydraulic chamber. Therefore, the
Discharge valve pressure in both chambers is identi­
cal. The diaphragm has the follow­
ing two functions:
h • To transmit the plunger displace­
ment of the hydraulic fluid onto
the metering fluid — under normal
operating conditions, the pressure
Spring * • on both sides of the diaphragm is
nearly identical
• To seal the operating fluid against
Hydraulic chamber
the environment at the diaphragm
Diaphragm
clamping area
Due to the oil leakage at the
plunger seal, a replenishing valve
well as slurries, thixotropic, high- properties: is needed. It opens when the dia­
viscous or non-lubricating fluids. • A diaphragm lifetime of at least phragm contacts the perforated
In terms of the hydraulic power, it 5,000 operating hours, depending plate. The hydraulic chamber can
makes sense to distinguish between on the operating pressure and the also be equipped with a safety valve
mechanically and hydraulically cou­ diaphragm deflection to prevent overpressure (not shown
pled diaphragms. • Diaphragm material with high in Figure 6). Figure 7 shows the op­
For low-pressure applications diffusion strength and chemi­ erating pressure as a function of
and smaller flowrates, pump cal stability. Many suppliers use time for a diaphragm pump, where
heads with mechanically coupled polytetrafluoroethylene (PTFE) or one can see the interaction of the
diaphragms have found a broad PTFE-coated rubber for this valves. In the diagram, the suction
market. At these pumps the dia­ • Multi-layer diaphragm with in­ and discharge strokes, the opening
phragm is directly assembled to tegrated diaphragm-monitoring time of the suction and discharge
the plunger, as shown in Figure system to indicate diaphragm valves, the compression and de­
5. The diaphragm has to seal and failure and guarantee tightness — compression phases and the open­
to convey fluid against the oper­ also after diaphragm rupture ing time of the replenishing valve are
ating pressure. This is the reason If the diaphragm is hydraulically clearly recognizable.
for the relatively small allowed op­ coupled, an operating pressure of As mentioned before, the dia­
erating pressure (up to about 20 up to 800 bars is possible with a phragm material is usually PTFE for
bars) compared with hydraulically PTFE diaphragm, and up to 1,200 pressures up to 800 bars and stain­
coupled diaphragm pump heads. bars is possible with a stainless-steel less steel for pressures up to 1,200
In many cases, the pump head diaphragm. These pump heads are bars. State-of-the-art for PTFE ma­
is combined with cam drives as used in a broad range of 0.1 niLTh to terial is a double-layer diaphragm
drive elements. Qualified designs about 60 m3/h. with integrated monitoring system
should have at least the following The principle design of a hydrau­ to indicate diaphragm rupture and

FIGURE 9. Pressure signals can be used to detect

leakage at the hydraulic chamber (right)

1—Head pressure, bar

t 90 A
Jil. W-y^l 1
1 1
70 1
1 1
50 'I 21.5 21.75
l Time.s
.
30
i ___________
/
10 ------
HIJfc
20 20.5 21 21.5 22 a 21 21.5
Time, $ Time, s

Operation unit without failure Operation with extended replenishing phase

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2019

 »

i ’•Aii.'.ia.xj an An j i«Vi

___ .., jr-

.
j L_____ ___ J L_______ earlier V'
slow compression —
Mj decompression
i
Pressure, barg

t 1 1i
i II \i
i1 1i
i
1I upset operation
ar* \r 1i

normal operation ^
i u *
I i j j _*!

(/ 11 *«
1]

/ i

-20 'kHmiuw*

FIGURE 10. This graph shows the change in the pressure signal when the suction valve is defective
—LEADER- IN-
to prevent leakage. The lifetime of a the stroke length afterwards. Figure -CHEMICAL----------
PTFE diaphragm can exceed 10,000 8 shows a modern, patented dia­
h operating time. Standard material phragm-pump head that prevents SOLIDIFICATION
for wetted parts, such as pumps this situation from happening. An
heads and valves, is stainless steel, installed spring tears the diaphragm —AND-----------------
for example 316Ti (1.4571). For spe­ to the rear position during standstill.
cific process requirements, these Easy and safe starting, even under ------ HANDLING-
parts can be made of special materi­ extreme conditions, is the result.
als, such as stainless steel 316/316L Furthermore, the spring ensures a -SOLUTIONS—
(1.4401 /1.4404), Hastelloy or Duplex stable diaphragm displacement and
steel and polyvinyl chloride (PVC). a significantly lower minimum-re­
When the suction line pressure quired suction flange pressure at the Granulation, solidification and
is below ambient pressure dur­ pump entry in many applications. handling systems for different
ing standstill, the start procedure kinds of chemicals like resins,
of a metering pump can be critical Condition monitoring waxes, hot melts, antioxidants
for the diaphragm. Due to very low The fluid valves and the diaphragm and stabilisers.
leakage at the suction valve and at are the major wear parts of the
• High productivity -
the piston seal, the diaphragm can pump head. In order to reduce
on-stream factor of 96%
move over time to the front dead lifecycle cost and to increase the
• Proven Rotoform technology -
point. If the piston has remained pump-head reliability, monitoring
2000 systems installed in
in the rear position, the diaphragm systems help to recognize devel­
30+ years
would be overstretched or dam­ oping failures at an early stage for
• Complete process lines or
aged at the first stroke after pump predictive maintenance. While the
retrofit of existing equipment
start. In order to prevent this, a spe­ double-layer PTFE diaphragms are
• Global service / spare parts
cific starting procedure is necessary. already monitored, the technology
supply
Pumps have to be started with zero to indicate and to predict valve fail­
stroke length and slowly increase ures is known [5-7]. The basis for
Read more at
ipco.com/applications

A valve failure in a diaphragm pump can

be detected by two intependent and
redundant signals. ipCO
f o r details visit adlinks.cltafnan9onlina.com/73SS7.20

CHEMICAL ENGINEERING WVWV.CHEMENGONLINE.COM SEPTEMBER 2019 47

 300

250
200
150
100
50 Pressure ] Time s
0 L
256.5 256.75 257 257.25 257.5 257.75 258 258.25

2 Defective suction valve

1
0
-1
■2
V
Acceleration

FIGURE 11. Defective suction valves can be detected with acceleration sensors

this monitoring system is a pressure
sensor to detect the operating pres­
sure as a function of time, as shown
in Figure 7, and an accelerometer
for acceleration measurement. The
accelerometer can be assembled
at the front of the pump head, while
the pressure transducer can be in­
stalled in the hydraulic chamber. At
commissioning, a fingerprint of the
signals has to be learned by the
system. Figure 9 shows the pres­
sure versus time diagram in nor­
mal (left) and faulty operation. The
replenishing valve in the hydraulic
chamber is open for a longer period
of time in case of leakages of the
hydraulic chamber (due to defective
piston rings or hydraulic valves). If
the suction valve is defective, the
compression starts later and lasts
longer, whereas the decompression
takes place earlier. This behavior is
shown in Figure 10. The reason for
this is fluid that is forced back into
the suction line if the suction valve
does not close properly although the
pump produces the operating pres­
sure required. In case of a defective
discharge valve, the compression
would be faster and decompression
slower. The existing pressure in the
discharge line supports the com­
pression and maintains the pres­
sure for a longer time period during
the decompression. In addition, the

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48
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2019
 4.^ Chemical

acceleration signal indicates clearly the defective suc­

tion valve, as shown in Figure 11. This shows that a
valve failure can be detected by two independent and
redundant signals.

Outlook
According to estimates by the German Association of
the Chemical-Pharmaceutical Industry (VCI), 9% of the
investment costs of a process plant in Germany are
accounted for by redundant pump systems [8], At the
pump side, the technology for monitoring valves seems
*
to be clarified. But we have a lack of field experience.
This could change in the course of the digitalization strat­
egy of the chemical and oil-and-gas industries. Compa­
nies, such as BASF, have declared that they want to use
data to better forecast maintenance requirements of their
plants and reduce unexpected shutdowns [9], And Shell
clearly describes the advantages of predictive mainte­
nance: “The objective is an increase in reliability of the
overall asset or part of the asset" (70). In connection with
the discussion of the internet of things (loT), it is to be
expected that the demand for condition monitoring and
predictive maintenance systems will continue to increase
MULTIPLE
for metering pumps as well. And that is a very promis­
ing development, because only intensive field experience TEMPERATURE
ensures enough confidence in these systems. ■
Edited by Gerald Ondrey POINTS
References
1.

2.
Fritsch. H.. "Metering Puncs (prinaplesL 0esign& AppicaUons).” Vtertag Modeme Industrie: Lands*
ber^Lech. Germany, 1990.
Sauler, M innovative Technotogien air Steagerung der Betoebsacherheit von Membfanpumpen,
ONESENSOR
PraWket Konferenz, April 16-18. 2007, Graz. Austria
Temperatures often vary within a
3. Vetter. G (ed): A Survey of Leak-tree Centrifugal and Positive Displacement Pumps, in: "Leak free
Pumps and Compressors.- Oxford. Elsevier Advanced Technology. 1995. manufacturing process. However, a single
4 KohTase, N. and Sritzefcerger, M, High Pressure Design of Engneerng Pumps, Chemical Erg
neemg Transactions. Vol. 2.2002,
Pyromation multi-point sensor can measure
5. KohTiase, N, Recordng the Heartbeat of Daphragm Pumps - Momlorng Systems Help to Re temperature at numerous points throughout
dxe Costs, Fruit Processing, June 2001.
the process. We manufacture a variety of
6 KoNhase, N. and Sauler, M. Storungsfruherkennung fur Prozess Membranpt/npen, Mustri-
epvwen inf - KompressorenAQii 2005. standard and custom RTD (PtlOO) and
7. Martinez. F, Phiipin, M. (fending. J. and ScrtXfcer. 6.: Dynamic Monferrig lor Early Falure Oag
noss and Moder n Techniques for Design of Rosflrve Displacement Pumping Systems, Proceedings
thermocouple multi-point constructions for
of 17t Pump Users Symposun. Turbomachmery Laboratory. 2000 applications including storage tanks, piping
8. Herod. R.. Trend: Conation Momtonng Systeme Kir Pumpen, wwwFlud.de.
systems, ovens/kilns/fumaces, airflow ducts,
9. www.bastcom/global/erVwihowe are/dgitalization html, July 2019.
10. www.shefl.ranVbusiness customefsAubficants-for-business/industry insights/the-benefits of-
grain bins, heat exchangers, railcar and truck
predctive maintenanceMml. July 2019.
tanks, chemical vessels and more.
11. Mlton Roy Metenng Pump Technology, Buletin 210. Revision July 2008.
12. vww.lewa de/de/pumpen/doaerpunperv4ewa intelktrive do®er membranptnpen/#c106306,
Jdy20i9
13. Lewa ecoHow-The Custom Made Metering Pinp.D1-160_en. January 2019.
14. www.sca solulionsoom/de/pcoducts/melering unfc^ Jtiy 2019.
GET A QUOTE!
pyromation.com/chemical
Author
Nils Kohlhase is professor for product development and sys­
260.209.6342
tematic design at the University of Applied Science in the Han­
seatic City of Lubeck (Technische Hochschule Lubeck, Monk-
hofer Weg 239. D-23562 Lubeck. Germany; Phone:

(£) pyromahon
+49-451-300-5780; Email: nils.kohlhase@th-luebeck.de). He
me.

has more than 21 years of experience in the chemical, oil-and-

gas. consumer and automotive industries. During this time,
Kohlhase was the technical manager at LEWA GmbH, director
R&D Europe at Trelleborg Sealing Solutions, manager PSD at
y beyond meosure
Leica Camera AG and global manager R&D at SCA Schucker
GmbH & Co KG. He is an expert in systematic product development and modular
system development. Kohlhase holds a doctoral degree (Diplom-lngenieur) in me­
chanical engineering from the Technical University of Braunschweig, Germany.
For details visit adlinks.chemengonline.conV73858*30

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