Industrial Dosing Pump Failures
Dosing pumps are the heart of chemical dosing systems. Failures can lead to chemical waste, process shutdown, and equipment damage.
1. Common Failures
1.1 Flow Rate Issues
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Low flow rate or no flow at all
- Causes: Airlock, clogged hose or valve, damaged pump diaphragm or piston.
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Uneven flow rate / pulsation
- Causes: Hose flexibility, diaphragm wear, pump head leakage.
1.2 Mechanical Failures
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Diaphragm / piston wear or perforation
- Result: Pump cannot dose chemicals correctly, leakage occurs.
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Hose cracking or rupture
- Result: Chemical leakage, process loss, safety risk.
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Pump shaft or motor failure
- Causes: Overload, insufficient lubrication, wear.
1.3 Electrical / Automation Failures
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Motor not running
- Causes: Blown fuse, loose connection, faulty motor driver.
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PLC or SCADA error
- Result: Automatic dosing does not work, process parameters cannot be controlled.
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Sensor failures
- Causes: Contamination, cable breakage, calibration deviation.
- Result: Incorrect dosing, process deviations.
1.4 Chemical-Related Failures
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Wear on pump parts due to corrosive chemicals
- Cause: Incorrect material selection (pump diaphragm or hose chemically incompatible).
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Chemical residue or crystal accumulation
- Result: Hose or valve clogging, reduced flow rate.
2. Preventing Failures
- Regular maintenance and calibration.
- Use of chemically compatible materials (stainless steel, PVDF, PTFE, etc.).
- Periodic replacement of pump hoses and diaphragms.
- Early warning system with flow and pressure monitoring.
- Operator training and safety procedures.
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