Republic of the Philippines

Batangas State University

Alangilan, Batangas City
College of Engineering, Architecture and Fine Arts
Mechanical Engineering Department

ME 518 – Fluid Machinery

DIAPHRAGM PUMP

Perez, Arvin Jun O.

ME – 5105

Engr. Ruben Celestial

Instructor

23 September 2018
What is Diaphragm Pump?

Diaphragm pumps are positive displacement

pump which move gases, liquids, or gas-liquid
mixtures via a reciprocating diaphragm. They are
highly reliable because they do not include internal
parts that rub against each other. They also contain no
sealing or lubricating oils within the pumping head,
meaning there is no chance of oil vapor leakage or
contamination of the handled media. They are able to
handle a wide range of fluids including corrosives and
those which contain solids. They providing leak-free,
low-maintenance operation and allowing the
diaphragm to safely pump abrasives, slurries, or even
run dry.

I. Principles of Operation

Diaphragm pumps are commonly called "mud hogs" and "mud suckers" because of their
use in pumping slurries and wastewater in shallow depths. They are capable of handling all sorts
of aggressive media including gases and gas/liquid mixtures, and can achieve very high
pressures. They should not be used to pump dangerous or toxic gases, since diaphragm pumps
are not hermetically sealed.

Larger models of this pump type are used to move heavy sludge and debris-filled wastes
from trenches and catch basins, applications where centrifugal pumps perform poorly due to high
discharge volumes and low water levels which would cause them to lose their prime.
Smaller models are typically used in chemical metering or dosing applications where
very constant and precise amounts of liquid delivery are required.

Diaphragm pumps work by flexing the diaphragm out of the displacement

chamber. When the diaphragm moves out, the volume of the pump chamber increases and causes
the pressure within the chamber to decrease and draw in fluid. The inward stroke has the
opposite effect, decreasing the volume and increasing the pressure of the chamber to move
out fluid. This operation is very similar to the draw in, push out, concept of human breathing.
 II. Major Parts & Subparts

Simple diaphragm pumps consist of a diaphragm, displacement chamber, two valves, and
a driving mechanism. The diaphragm is made of a flexible material compatible with the pumped
media. It is sealed in place between the side of the displacement chamber and an attached flange.
The chamber's volume is slightly greater than what the diaphragm can displace. The valves are
typically spring-loaded ball valves or flapper valves made of the same material as the diaphragm,
and they function to admit the fluid in and out of the chamber. The driving mechanism is what
flexes the diaphragm - in the diagram below, the drive mechanism is a spring activated by a
solenoid.

III. Preventive Measure

All the following items shall be checked/recorded after the specified period.

After 1000 Hours

i) Crank case oil condition for contamination

ii) Gear Box oil condition for contamination
iii) Gland for leakage Note 3
iv) Coupling guard condition (shall be rectified if necessary)
v) Motor and Gear box bearings by sound and temperature (in running condition)
vi) Relief valves for passing
vii) Lubricating oil pump and non-return valve (for steam driven pump only)

After 4000 Hours

i) Crank case oil replacement (crankcase shall be flushed before oil replacement)
ii) Gear box oil replacement (gear box shall be flushed before oil replacement).
iii) Condition of piston/plunger and liner for wear
iv) Lubricating oil strainer and pipings
 v) Bearing and Gear of Gear box for any damage
vi) Coupling guard condition
vii) Working of safety relief valve
viii) Ensure replacement of gland packing
ix) Alignment
x) Suction and discharge valve, valve seat etc.
xi) Stroke adjusting mechanism (shall be serviced if necessary)
xii) Lubrication for the steam driven side (in case of stream driven pump)
xiii) Foundation, foundation bolts and supports
Note: The pump shall be started after completing the checks listed i to xii above and the
following shall be checked:

a) Vibration and temperature of bearing of Gearbox and Motor

b) Gland for leakage (shall be adjusted if necessary)
c) Pump performance

After 8000 Hours

Complete overhauling of the pump shall be carried out. This shall include part-wise
inspection and all checks specified for 4000 Hours.

Part-wise inspection shall be carried out during complete overhaul.

a) shall be checked for condition and elongation

b) shall be replaced if dimensions don’t match with original values.
c) lube oil sump shall be flushed and oil replaced.

Parts Replacement Schedule Reason

Diaphragms have multiple

Generally, not to exceed a
period of 2 years. Depends on
Diaphragm
customer SOP, operating time
and fluids.
layers to improve flexibility
and strength, which can be
contaminated if left
unattended for long periods,
depending on the fluid
makeup.

Clean, sharp-edged seat allows

flow through the pumping
chamber. Low or fluctuating
Check Valve Annually
flow rates can occur when dirt,
scratches, or worn valve
seatings occur.

Rapid exchanges of air follow

the stroke speed. Keeping the
Air Filter Annually wire mesh path clear allows a
smooth exchange of air. A
dirty filter can become a
source of unstable hydraulic
 balance and an external barrier
growth location.

Gear Oil Annually Ensure maximum efficiency.

Lubrication is dependent on
splashing. Slow motor speeds
for long periods of time can
limit the lubrication to this
Upper Bearing Every 4,000 hours
bearing. Improper settings
could result in reduced pump
output or system component
damage.

Improper settings could result

Pressure Relief Valve (PRV) –
Annually in reduced pump output or
Check or reset pressure setting
system component damage.

IV. Troubleshooting

Pump will run but will not pump.

 Check suction line for leaks.

 Tighten bolts or clamps on suction manifold of pumps.
 Material too viscous to pump at high rate of flow -slowdown pump by reducing air
supply pressure to pump or use larger diameter suction line.
 Suction manifold & pump chambers misaligned -disassemble & realign.
 Suction or discharge balls jammed open with foreign object -disassemble pump and
remove foreign object.

Severe pump vibration with intermittent flow.

 Ruptured diaphragm- disassemble pump, replace diaphragm and clean air valve if
necessary
 Mechanical failure - disassemble pump and inspect for bent shaft, ruptured diaphragm,
other part failure.

Product discharged from exhaust outlet.

 Check for diaphragm rupture.

 Check tightness of diaphragm nut.

Air bubbles in product discharge.

 Check connections of suction plumbing.

 Check “O” rings between intake manifold and fluid caps.
 Check tightness of diaphragm nut.

Low output volume, erratic flow, or no flow.

 Check air supply.

  Check for plugged outlet hose.
 Check for kinked (restrictive) outlet material hose.
 Check for kinked (restrictive) or collapsed inlet material hose.
 Check for pump cavitation − suction pipe should be sized at least as large as the inlet
thread diameter of the pump for proper flow if high viscosity fluids are being pumped.
Suction hose must be a non-collapsing type, capable of pulling a high vacuum.
 Check all joints on the inlet manifolds and suction connections. These must be air tight.
 Inspect the pump for solid objects lodged in the diaphragm chamber or the seat area.

Varying pump discharge per stroke.

 Remove suction manifold and chek for obstructions.

 Worn or leaky ball valves & seats - disassemble pump and replace worn parts.
 Check to verify bolts are fastened tightly and re-torque if necessary.

Slowing of pumping action

 Clogged air exhaust muffler – clean or replace

 Ice build-up in air valve - install de-icing device on air inlet line.

V. Overhauling and Repair

1. Remove the bolts that attach the valve chamber(s) and remove the covers and old valves

2. Remove the bolts that attach the diaphragm covers or the diaphragm/valve covers

3. Remove the old valves and o-rings and discard them.

Note: Do not use old valves or o-rings when overhauling pump; they will not make a proper seal!
4. Clean all the heads, covers, and valve chambers thoroughly of any rust or build up. Make sure
that the machined lip of the diaphragm cover is clean to allow proper seal.

5. Un-bolt the diaphragms from the connecting rods and discard all diaphragms.

6. Remove the diaphragm backing discs and inspect the pump.

1. Check the crankshaft for sufficient grease.

2. Look for any signs of excessive wear or internal damage.

3. The connecting rods will have side to side movement, but no up and down play.

4. If up & down movement is present then further tear down is necessary, go to step-7. If
connecting rods are in good shape then skip to step-14.

Note: Use steps 7-13 if connecting rod wear/damage is detected.

7. The pump housing splits into two separate portions. Remove the bolts that hold the pump
housing together.

8. In order to separate the housing on the larger pumps place a socket on the rear of the
crankshaft just large enough to cover the grease zert. Using a dead blow hammer strike the
socket in order to separate the two housings. Once a gap is created carefully pry the two portions
of the housing apart.
9. Remove and inspect the connecting rods (they should be smooth). If any grooves, chips, or
cracks are detected then the rods will need to be replaced. 10. Continue to tap on the rear of the
crankshaft until it can be removed from the housing.

11. Rotate and check all bearings, if they are loose or have any rough or worn spots replace
them. Using a press remove the bearings and replace any that are damaged. Note: Pack the
bearings with a lithium based grease.

12. Reinstall the crankshaft using a dead blow hammer leaving a ¼” of the rear carrier bearing
showing.

13. Set the pump with the PTO-Shaft end facing up and install the connecting rods. Tap the
crank shaft the rest of the way in and re-install the housing.

14. Install the diaphragm backing disc and new diaphragms with the bolt and retaining washer,
make sure the lip of the washer points away from the diaphragm.

15. Rotate the shaft so that the diaphragm is in the up position and torque the connecting bolt to
the correct lbf-ft.

16. Then install the o-rings around the valves and lubricate the o-rings and metal surfaces with
vegetable oil. Warning: Do not use a petroleum based product it will damage the seals!

17. Lubricate the machined area of the diaphragm cover/valve cover and diaphragm with
vegetable oil.

18. Make sure the diaphragm is in the up position and torque the diaphragm cover/valve cover to
the correct lbf-ft

19. Install the o-rings on the valves and lubricate the o-rings and metal surfaces with vegetable
oil. Re-install the valve chamber(s) and torque to the correct specifications. Warning: Do not use
a petroleum based product it will damage the seals!