Stable process water management: From recurring operational problems to reliable pump pits
For operations and maintenance managers, pump pits are often a recurring risk point. Media with particles and sludge can quickly lead to clogging, increased maintenance efforts and unplanned downtime.
For a company in the metal industry this was a recurring challenge. The customer tried several pump types, but none provided a long-term solution. To solve the problem, the customer needed more than a new pump. They needed a solution that could handle real-world operating conditions over time.
By testing the right technology directly in the process, we at Colly Flowtech were able to ensure a solution that created reliability, reduced maintenance and predictable operation. We chose an air-operated diaphragm pump and tested it directly in the customer's real operating environment.
The challenge: Particulate matter, sludge and lack of long-term function
The customer's challenge was that the pump pit handled all the process water in the plant and was therefore a critical function for operation.
The media handled by the pump pit also contained particles and thicker sludge that caused recurrent breakdowns and increased service needs. This meant that previous solutions worked in the short term, but not over time.
The challenge was therefore to find a solution that:
- Handles varying media with particles and sediment
- Handles the desired flow and pressure
- Minimizes clogging and wear
- Reduces maintenance and downtime
- Works stably in real operation, not just to specification
In other words, the customer needed not just a pump that works, but a solution that works long-term in a demanding application.
The solution: Air-operated diaphragm pump with flap valves for difficult-to-pump media
We at Colly Flowtech acted quickly thanks to our local availability. We had a test pump in stock and sent it directly to the customer for on-site evaluation.
For the application we chose a air-operated diaphragm pump with flap valves from Versamatic.
We based the choice on the actual challenges of the application:
- Flap valves allow passage of larger particles and sludge
- The suction capacity of the pump allows settled material to follow
- Air-powered design provides robust operation in harsh environments
We chose the air-operated diaphragm pump specifically because it handles particles and sludge without causing recurrent clogging.
By testing the solution in real-life operation, the customer was able to verify functionality, reduce risk and make decisions with high confidence.
A solution built for hard-to-pump media, but equally for stable operation and reduced maintenance.
The result: Less downtime and a stable pump pit
After the test period, the effect was clear. The air-operated diaphragm pump created a reliable solution for the pump pit, reducing the need for maintenance and greatly reducing downtime.
The effects were:
- Stable management of process water
- Sharply reduced maintenance
- Less downtime
- Increased predictability in a critical function
The biggest gain was long-term performance. An application that had previously been a recurring problem became stable thanks to the choice of an air-operated diaphragm pump.
Testing the right solution in operation reduces risk
The project shows the value of being able to test the right technology in the customer's own process. With local availability and application understanding, we at Colly Flowtech were able to quickly verify the solution and create security throughout the entire purchase journey.
When the right pump type is combined with practical validation, the risk is reduced and the likelihood of a long-term functioning installation increases.
Do you have a pump pit that requires too much maintenance? Are you an operations or maintenance manager experiencing recurring pump pit stoppages, clogging or servicing?
Want to know more about how we can help you choose the right pump and materials for demanding media in your process? Contact us (oskar.karlsson@colly.se) or (mattias.steffl@colly.se) and they will be happy to tell you more.
Explore our range of Air Operated Diaphragm PumpsDo you have any questions?
Oskar Karlsson
