discflo pump maintenance manual

discflo pump maintenance manual

Their unique pumping mechanism is based on the effect of a boundary layer and viscous drag principle, which produces a pulsation-free laminar flow. This technology creates a low-to- no maintenance system by minimizing contact between the pump and the raw material being pumped. The results speak for themselves. Wear on the disc pump components is greatly reduced resulting in pump longevity, reducing operational costs and saving hundreds of thousands of dollars in parts, maintenance and product loss. The powerful combination of superior abrasion resistance, gas-entrained pumping ability and non-emulsifying laminar flow make the Disc pump the ideal choice for the toughest applications. Discflo defines RELIABILITY in pumping. Founded in 1982, the company has built a world-wide reputation designing pumps to solve some of industry’s toughest pumping problems, replacing centrifugal, eccentric, progressive cavity, lobe, gear and even chopper pumps in applications as diverse as waste-water treatment, offshore oil platforms, pharmaceutical manufacture and mining. Pump Solutions Discflo leads the world in slurry pumps, abrasives pumps, cantilever pumps and waste-water pumps. Only the best, for the toughest. Our team will be happy to contact you regarding product inquiries or request for additional literature. We pride ourselves on being a resource for our clients, providing solutions that save you time and money. Discover everything Scribd has to offer, including books and audiobooks from major publishers. Start Free Trial Cancel anytime.http://www.w3.org/2000/svg" xml

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Report this Document Download Now Save Save Manual de Operacion Discflo For Later 0 ratings 0% found this document useful (0 votes) 33 views 42 pages Manual de Operacion Discflo Uploaded by Jorge Paez Description: Manual Bomba Discflo Full description Save Save Manual de Operacion Discflo For Later 0% 0% found this document useful, Mark this document as useful 0% 0% found this document not useful, Mark this document as not useful Embed Share Print Download Now Jump to Page You are on page 1 of 42 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language. Get Started Login here Discover how Gerber Pumps can help you with your 'hard to pump' fluids and sludge. You purchase 'Peace of Mind' when you install a DISCFLO pump. From the outside they look like very robust end suction centrifugal slurry pumps in that they rotate as a standard centrifugal pump. However, internally, the unique and worldwide patented “discpac” design makes all the difference in performance of the Discflo pumps. Additionally, the pumped product is transferred in the most delicate and gentle manner due to Discflo's laminar flow 'pull through' pumping principle. Discflo pumps exhibit the Simplicity of Centrifugal pumps with the Solids Handling capabilities of Positive Displacement pumps.' Be the first to review! Change File Login here. Find your next solution on WEF Buyer's Guide - now owned and operated by WEF! Disc pumps have no close tolerances and deliver laminar, pulsation-free flow. They can also pump air or gas entrained fluids, up to 80% by volume, and large or stringy solids, without clogging. The Disc Pump's unique non-impingement Discpac 'impeller' prevents degradation, emulsification and damage to delicate and shear sensitive products. In many cases, they are retrofitted to replace failed centrifugal, progressive cavity, lobe, gear and chopper pumps.http://www.ssu.kiev.ua/admin/fckeditor/editor/filemanager/connectors/php/userfiles/dodge-6-speed-manual-transmission-rebuild-kit.xml

The Discflo submersible pump is designed without close tolerances to handle large and stringy solids without clogging.Using the unique Discpac technology, these pumps provide clog-free, low cost, long-lived operation, outperforming progressive cavity, centrifugal, lobe and chopper pumps in even the toughest installations. Sump Disc Pumps have a low NPSH requirement. Using the innovative Discpac technology, these pumps offer a superior alternative to centrifugal, progressive cavity, lobe and gear pumps for viscous, abrasive, high solids, and gas-entrained fluids as well as handling shear sensitive and delicate chemicals and emulsions.Both series meet 3-A sanitary and international hygiene standards and USDA requirements. They can be supplied in Clean-in-Place or Steam-in-Place versions, and in a variety of metallurgies to meet the user's requirements. They are designed for processes up to 1000 degF, and allowable working pressures to 1480 psi. Flow ranges to 8000 GPM can be accommodated, with heads up to 1200 ft. They have quiet, pulsation-free operation and low NPSH requirements. Plus, the cantilever pump has been proven to have low radial and axial loads, further improving its reliability in handling tough fluids and for hard-to-reach installations. Cantilever pumps are available in a wide range of construction materials and sizes. This process produces a non-stick surface on the wet end parts to prevent grease and Struvite build-up. The super-durable glass-lined surface also reduces wear inside the pump, increases pump life and greatly improves resistance to corrosion, abrasion, high temperatures and thermal shock. Glass-lined pumps have been shown to perform better than epoxy-lined pumps in abrasive and corrosive service. These pumps also handle fluids containing high amounts of entrained air, for example anaerobic sludge or DAF sludge, without cavitating.

Wide Range of Configurations, Sizes, Metallurgies A wide range of standard Disc Pump models and sizes are available, including over-under, side-by-side, submersible, dry pit, cantilever and sump pump configurations. Flow rates to 10,000 GPM and. The South Central Regional Wastewater Treatment Board of Delray Beach, Florida was using centrifugal trash pumps for their lime slurry application, however the plating out was creating problems for their pumps. Since the impeller of a centrifugal pump must be balanced on the shaft, and as the lime builds up on the impeller, balance is lost and the impeller and shaft wobble. The imbalance destroys the seal and creates a condition that often destroys the motor as well. In most lime slurry applications there is additional abrasive solid content that complicates things even further. At Delray, grit and pebbles quickly wore down the centrifugal trash pumps, even with their wider clearances. In the end, the pumps were too costly and labor intensive to keep running so the city switched to a diaphragm pump. As the lime plates out, it coats the check valves so that they can't close completely. These check valves must seal completely or the slurry is pushed backward into the inlet or suction side. In addition, grit and pebbles that accumulated in the diaphragm-pumping zone during off times caused excessive stress and ruptured the diaphragms. Caked with lime and battered with grit and rock, the pumps didn't hold up well. They required maintenance about every other day to keep them running. They have built a strong reputation for getting results with hundreds of successful pump installations in treatment plants throughout the southeast. In March 2000, Bob Hagle, the executive director of South Central Regional Wastewater Treatment Board of Delray Beach contacted Gerber Pumps. He was looking for a solution. Gerber Pumps recommended a pump from El Cajon, California-based Discflo Corporation.

Working closely with South Central Regional Technical Specialist Dane Anderson, maintenance chief of the South Central Regional Wastewater Board, a system was designed that finally ended the maintenance nightmare and high costs of the lime slurry application. (Return to top) Discflo pumps fit neither category. This is what makes it different from other conventional-type pumps. This difference has significant advantages that provide a real option for end-users with difficult or shear-sensitive applications. As a fluid enters the pump, its molecules adhere to the disc surfaces and form a protective boundary layer that remains stationary, relative to the rotating discs. As the discs rotate, energy is transferred to successive layers of molecules in the fluid between the discs through viscous drag. This generates velocity and pressure gradients between the discs. The combination of boundary layer and viscous drag does two things, 1) it protects the moving parts of the pump, and 2) it creates a force that pulls the fluid into the pump in a smooth, pulsation-free flow. Because of its unique non-impingement pumping, the Discflo pump suffers little or no wear, even under the harshest abrasive conditions and has almost no impact on shear-sensitive fluids and delicate products. (Return to top) For this pump, however, this was not an issue. Buildup can reduce the overall capacity of the pump at a given RPM by a small amount, but it has no affect on the performance of the pump. The Discpac and rotating element remain balanced, seals are protected, and the pump maintains a smooth, laminar flow. In fact, in this application, abrasives solids can help by preventing excess lime build up on the Discpac surfaces. The various pressure gradients and hydraulic shearing action between the discs create an equilibrium of the plated lime so there is no excess accumulation on the discs and the boundary layer maintains an effective operating thickness.

(Return to top) The back pullout design makes removing the Discpac for cleaning simple. Unlike centrifugal pumps, there are no exact tolerances to worry about. The lime slurry pump at Delray has been in operation since April 2000 and has required no maintenance. The complete elimination of maintenance has saved the plant thousands of dollars in just this first year of operation. This application represents the typical Discflo pump performance in lime slurry and sludge applications, according to the manufacturer. It is in stark contrast to the near-constant maintenance that is required to run conventional-type pumps under the same conditions. (Return to top). Engineers and treatment plant operators are taking notice; Bert Gerber reports that there has been much interest, and it has resulted in several current lime slurry projects in Florida alone. Coral Springs Improvement District recently installed three Discflo pumps for lime slurry. The City of Moorehaven, Florida has placed an order for one lime slurry pump that is currently in production, and the City of Gainesville has designed an expansion project that will include six Discflo lime slurry pumps. In many cases, the life cycle costs have been reduced by 90% or more. Discflo pumps come in over 20 models and can be configured for a wide variety of operating ranges and fluid conditions. (Return to top) Some of Discflo Corporation's product offerings include: ANSI Pump, Disc Pump and Disc Mixer. Visit the Water Online Buyers Guide for more information on pump products, suppliers and applications. Learn more. By visiting this website, certain cookies have already been set, which you may delete and block. By closing this message or continuing to use our site, you agree to the use of cookies. Visit our updated privacy and cookie policy to learn more. Learn More By visiting this website, certain cookies have already been set, which you may delete and block. Visit our updated privacy and cookie policy to learn more.

Pumps suffer rapid wear under the abrasive assault of particulates. The viscosity in products like latex can choke the pump and even break the steel shafts, while the pressure and agitation cause it to set. In turn, the pumps beat, and paddle, and otherwise abuse delicate products. Turbulence and pulsation can even introduce air bubbles, which can reduce the quality of some products.Too often, the industry has settled for excessive pump operating costs and staggering product losses, as much as 50% in some cases. These losses would be considered unacceptable in any other industry. Types of PumpsIn a centrifugal pump, fluid enters at a high speed and is thrown against the casing by impellers. Another group uses positive displacement, meaning liquid is displaced with each revolution of the pumping elements. This is done by trapping liquid between a pumping element, commonly gears, lobes, rotary pistons, vanes, or screws and a stationary casing. Reciprocating pumps use a piston moving back and forth in a cylinder with valves that regulate the flow of liquid. All of these systems have one thing in common — they use a device to impel or push the fluid through the pump.It is moved in slurries that can average as much as 70% solids content by volume — literally liquid sand.They are one of the most versatile, widely used and commonly understood industrial-application pumps. They come in all different sizes and configurations. For abrasive applications, they can be made of special resistant metallurgies and fitted with protective rubber linings. They need this help because, in reality, the centrifugal pump has the worst possible design for pumping abrasive product. Abrasive HandlingThese tolerances wear away in abrasive service and the pumps steadily lose efficiency and eventually fail. The abrasion resistance of any pump design depends on the flow path of a solid as it passes through the pump. If the particle makes contact with a surface, the surface will wear.

The amount of wear depends on the impingement angle (angle of attack) at contact and the relative velocity between the abrasive particles and the pump surfaces. To solve this problem, centrifugal pump manufacturers have attempted to reduce impingement by lowering the impeller vane angles.The larger pump will cost more to buy and generally operate with lower efficiency. Even after making these concessions, the slower pump could have more trouble with the solids. When fluid velocities fall, the solids can fall out of solution and clog the pump. In many cases, product would have to be diluted to get it through the pump. A more suitably sized, faster running pump will do the job more efficiently, but have a shorter, maintenance-intensive life.This pump can be used in applications including paint, chemicals and food. It generates a pulsating flow, produces less shear than a centrifugal pump, and is relatively inexpensive.The valves can wear quickly and need constant attention. One end user called it nuisance maintenance, but it can also translate into expensive downtime. For another it was disastrous, as the particles worn from the ball valves contaminated their expensive product. For many other end users, their pumping difficulties seem so unsolvable that their attitude becomes “I know it’s going to break down so I want the least expensive pump for that job so I can afford to replace it.” However, the operating costs of a diaphragm pump can be 10 times that of a standard centrifugal, and replacing the pump four times a year or more in abrasive applications can be expensive.The operating principle behind the disc pump is called boundary layer-viscous drag. Its application to pumps is new, but it has been used widely in fluid engineering for over 100 years. A common example of this principle is the phenomenon of pressure drop or friction losses through a piping system.The stationary pipe exerts a “drag” force on the flowing liquid.

The velocity of the layer adjacent to the pipe is zero where the drag force is the strongest. Successive layers flow increasingly faster with the highest velocities at the center point between the pipe walls.The pump uses a series of parallel discs called the Discpac. The discs create “drag,” and an initial “boundary layer” of fluid adheres to their surfaces as flow enters the pump.With rotating discs, the boundary layer is stationary relative to the discs. If we were standing on the discs, the boundary layer would have zero velocity. This means that it is at rest on the discs — thereby it is traveling at the same velocity. The streams at the center of the Discpac would be flowing with the fastest velocities. Relatively speaking, someone standing outside the pump will see that the “stationary” fluid layer on the disc surfaces has the highest velocity with fluid layers at the center between the Discpac having the lowest velocities. This creates a powerful dynamic force that “pulls” the product through the pump in a smooth, pulsation-free flow.The non-impingement pumping has some compelling advantages over traditional pump choices in handling difficult and shear-sensitive fluids. Disc Design The discs that are the pumping mechanism in the disc pump rotate in a plane perpendicular to the pump inlet so that the fluid flows are parallel. Except for the initial uptake of fluid, there is no contact or impingement between the pumpage and the discs. The impingement angle of the solids as they exit the Discpac is close to zero. Even if contact is made, it has little force and with a boundary layer fluid buffer, little or no damage results to pump or to product. Higher SolidsAt this level, almost any pump will have clogging problems, but slurries containing up to 80% solids by volume can be pumped without clogging a disc pump. In-house testing at Discflo has shown that particles in slurries with a solid content of up to 40% pass through the pump without contact.

At higher levels, there is still very little contact. This non-contact fluid handling can reduce pump wear by 80%, even in the most abrasive service conditions. Application InfoA disc pump replaced a centrifugal pump with very good results. A recent inspection revealed that after more than a year of service, there is very little wear inside the pump. This was achieved without the linings that were required with the old centrifugals. This is not trivial. The rubber linings had to be replaced every 18 days. It is a labor- and time-intensive task and, because linings all look the same, it was common for an incorrect liner to be used. With an ill-fitting liner, the pump could go down in a single day.During this time, three inspections have been done. The last showed a small amount of wear on the casing, but because the system requires a 3” suction line (inlet side) feeding a 6” discharge, the pump is almost certainly in a full state of cavitation. CavitationIt can happen when liquid in the low-pressure area of the pump vaporizes. Vapor bubbles implode as they pass to regions of high pressure and can create a shock wave powerful enough to lift metal off the pump. The energy required to accelerate the liquid to high velocity and fill the void left by the bubbles causes a drop in capacity. Because the flow is laminar throughout the disc pump, there is minimal pressure loss and the risk of cavitation is reduced. Even when it does occur, the disc pump is relatively unaffected because it is protected by the boundary layer of fluid.In this case, the disc pump feeds the Ti0 2 slurry to a dryer. Previous pumps had required more carrying fluid to move the Ti0 2 to keep them from clogging. In fact, the suction side had to be hosed almost continuously to keep the centrifugals running. More fluid means more energy is spent in the drying process. The disc pump has wide internal clearances that have an affect on energy efficiency.

Obviously, this design has advantages and disadvantages. Wider clearances reduce clogging and give the pump excellent handling capability in pumping abrasive and shear-sensitive materials. Another advantage is that there is no efficiency loss due to wear. The downside is that wider clearances reduce the pump’s efficiency in water-like applications.A distinctive characteristic of the disc pump is that its pumping efficiency increases as viscosity rises. At viscosities greater than 350 cPs, the pump is actually more efficient than a comparatively sized centrifugal pump in a similar application. The difference is illustrated in Figure 3, showing velocity profiles across the Discpac at viscosities of 1 cP and 5,000 cPs. At 5,000 cPs, the disc pump transfers about 25% more volume for the same horsepower and at 660 cPs, the disc pump will require half the horsepower of a similarly sized centrifugal pump. The disc pump can handle heavy viscosities up to several hundred thousand cPs.In this particular case, the efficiency of the process was greatly increased because of a shorter drying time.Like Ti0 2 slurries, abrasives have a high content that can make them hard to pump. They pose an additional difficulty as well; they are adversely affected by shear in the pump that is created by impingement and flow turbulence. Clay slurries thicken and can even set to a solid when subjected to the pressure and agitation of pumping.An old technology, a progressing cavity pump is a positive-displacement pump using in its basic form a single spiral-shaped rotor that turns eccentrically in a double-threaded stator. As the rotor turns, a series of sealed cavities progresses from inlet to discharge. This produces a continuous pulsating flow along a limited path through the pump. A compression fit that acts much like an o-ring sealing between stator and rotor makes the pump relatively efficient. However, this efficiency is gained at the expense of the ability to handle solids and abrasion.

As with centrifugals, stators made of elastomer materials can be used to help the pump withstand abrasion, but when you have solids passing through a pump with extremely close tolerances, excessive wear and maintenance are a constant and unhappy fact of life.The track record for progressing cavity pumps was an unimpressive and expensive few weeks to a month for one producer who makes a 72.5%-solids calcium carbonate slurry used in a coating for fine paper. Crystals in the coating are specially engineered and are, says the distributor, “like pumping needles.” This combination of abrasion and shear was disastrous. After just a one-week demo trial with the disc pump, the company was completely convinced and purchased three more. Broken shafts became a thing of the past.The product is delivered to this customer by truck in slurry form and is pumped into holding tanks. Now when the truck pulls up, a disc pump is online and, because it is very efficient with viscous fluid, it empties the tank in 20 minutes — about half the time it took before. This is typical performance for disc pumps in an abrasive application with higher viscosity levels.In pumping emulsions, independent testing has shown that the disc pump has little impact on the product. In one test, a mixture of oil, water and detergent was circulated for 30 minutes through five conventional-style pumps and a disc pump. The amount of shearing, emulsification and disintegration for each pump was investigated, and then a sample was filtered through a membrane. The results are shown in the table.The pumping is so smooth that shear in the pump is less than it is in the discharge piping.There is an inherent difficulty in working with latex products. Any kind of impact — whether pump on fluid or fluid on fluid — negatively affects the quality of the product. Many producers don’t understand why, no matter what kind of fluid handling system is designed, their products still suffer.

A stable, consistent viscosity is fundamental to the quality of most inks and coatings. Latex products are especially vulnerable. Friction in the pump generates heat that congeals it. In congealed form, it coats the interior surfaces of the pump and fills the stuffing box, destroying the seal. Clumps of latex particles clog the pump and the piping, and plug strainers and filters down-line. Not only that, congealed latex is product that cannot be sold.One end user had tried several kinds of pumps but all produced shear that created latex solids in high concentrations. They wreaked havoc on the pump and then moved downstream and clogged the filters. The company reported, “In less than a month of operation, the Discflo pump has increased productivity approximately 12% by eliminating the latex solids produced by shear.” The increased productivity figure does not include filters or downtime.The Discflo pump does not suffer in latex pumping the way conventional-style pumps do. Discflo has pumps in latex applications that have been in continuous service for more than 10 years. Disc pumps are widely used for shear-sensitive dispersions and emulsions and are employed in the manufacture and processing of components in today’s industrial and decorative coatings — resins, polymers, monomers, acetates, silicates, alkyds, all kinds of pigments, and a host of finished products. In applications where abrasion, shear-sensitivity, high-solids content, viscosity and other difficult fluid conditions exist, disc pumps can provide a real solution and introduce new economy for processes where profitability has been hampered by high maintenance costs or unacceptable product degradation. A majority of the industry’s biggest and best producers have already found that out and depend on the handling characteristics of disc technology for many of their most challenging pumping processes. AcknowledgmentsTell me how we can improve. Please tell us why. Learn about how they work and how their uses.

There are two classes of dispersers to grind material- high shear disperser blade rotating at a high speed and bead mills that use grinding media. We will discuss the differences. A mechanical force moves the media at a rapid speed creating a shear force by collisions and rolling movements. This is especially important when dealing with multi-component products and large supply chains. Unique in design, the Disc pump bridges the performance gaps of conventional pumps and is capable of outperforming all of them in many applications. The Discflo pump uses a new and patented technology that isn’t available in any other pump. The technology of the Disc pump harnesses the natural power of boundary layer and viscous drag. Look at the total costs of buying and operating a pump and take into consideration downtime, labor, spare parts, and changes in product yield or quality, you will find that there is no better buy than a Discflo Disc pump. This creates a natural, protective buffer that separates the pump from the fluid. The boundary layer attracts and drags successive layers of fluid molecules into layered flows of parallel streams. This is the simple principle of viscous drag and in the Disc pump it is a powerful dynamic force that “pulls” the fluid through the pump in a smooth laminar, non turbulent flow. Rotary discs provide non-impingement pumping — that means less wear and greater protection for your product. Features The DiscPac It is the Discpac that makes the Disc pump so revolutionary. This impact is hard on shear-sensitive products, and it creates pulsation that wears the pump and damages piping. The non-impingement operation of the Disc pump makes it different than any other pump on the market today. The Disc pump uses a series of parallel discs called the Discpac. As the discs rotate, they create a boundary layer and viscous drag force that pulls the product smoothly into the pump. There is no destructive impact with an impingement device.

Versatility The Discpac can be designed for the gentlest possible pumping of shear-sensitive solids and gaseous froths. At the same time it can handle aggressive slurries with heavy viscosities and highly abrasive solids content. The Disc pump can be designed with over-size suction and discharge. A wide variety of metal and non-metallic materials are available for the pump and its components and over a dozen configurations including API-610 and ANSI 2000 using Disc technology. Low NSPH Requiements Laminar flow means low NPSH. It prevents reduction in head and capacity and further reduces noise and vibration. The NPSHr is about half to one-third of a centrifugal pump in the same service conditions. It also eliminates pump vibration and excessive noise. The open design prevents clogging. Optional pull out back. Options Customised Sealing Options Sealing Wide range of sealing arrangements available to meet service conditions. Seal chambers Optimum seal design for wide range of sealing options, including tapered and oversize bores. Prevents premature bearing failure due to oil loss and contamination. Lubricant Users can easily convert from standard oil to oil mist or grease if desired. Heavy duty shaft and bearings Minimal shaft deflection at seal faces. Average bearing life of 10 years even in tough operating environments. You can opt out at any time. Click here to read our privacy policy for full details. Let’s Connect Get in touch with our dedicated team. We are here to help. Terms of Use Privacy Policy Conditions of Sale This website uses cookies to improve your experience. We'll assume you're ok with this, but you can opt-out if you wish. Out of these cookies, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website.