2AGENDAPeristaltic Pump TheoryPeristaltic Pump Features & BenefitsPeristaltic Pump LimitationsRoller versus Shoe TechnologyHose lifeDulcoFlex product lineDulcoFlex featuresApplicationsSummary
3DulcoFlex History Date Event 1995 Boyser Bombás founded by Juan Jofresa in Barcelona Spain2001Fisher Process Industries signs a 5 year exclusive distributor agreement with Boyser Bombás to represent the Boyser peristaltic pump in North America.2006The agreement is extended and Periflo pumps now markets themselves as a manufacturer01/01/2009ProMinent Fluid Controls of Heidelberg Germany purchases Boyser Bombás.10/04/2010Pulsafeeder purchases Periflo Pump Company from Fisher Process Industries
4DulcoFlex History Date Event 10/31/2011 Periflo Pump’s contract with Boyser Bombás is cancelled.02/23/2011ProMinent USA launches the Boyser Bombás product line under the DulcoFlex trademark.04/19/2011Periflo Pumps is now directed to purchase all Boyser Bombás products through PFC USA04/20/2011Periflo Pumps ceases to purchase pump components from PFC USA
5Peristaltic Pump Theory Per·i·stal·sis (per·i·stal·ses) n. pl.The wavelike contractions of a tubular structure that propel the contents forward by alternate contraction and relaxation.As the rotor of the pump rotates the fluid is gently pushed forward until it is expelled through the discharge. In a peristaltic pump this occurs twice per revolution.Very similar to our esophagus. Food is introduced into the gullet and the esophagus gently constricts to force the food towards the stomach.
6Peristaltic Pump Theory Peristalsis is regarded as one of the simplest and most efficient means of pumping fluids.
8Peristaltic Pump Features & Benefits Seal-less DesignWith the hose being the ONLY contact point of the material, there is no need for any sealing devices whatsoever!Other PD pumps require mechanical seals, packing glands or ball checks.Since the fluid is held hostage inside the hose, no mechanical components are susceptible to corrosion and wear.
9Peristaltic Pump Features & Benefits Accurate dosing.Because of such a high volumetric efficiency, the hose and tubing pumps make excellent dosing and metering pumps.With repeatability they are accurate to +/- 1% when dosing and metering.Note: the accuracy is based on new hoses/tubes. Eventually they will start showing a decline in performance as they will not open completely which negates the high metering accuracy.
10Peristaltic Pump Features & Benefits Self PrimingThe peristaltic hose pump is the ONLY PD pump capable of pulling a “dry” vacuum of 29.5 feet (9 meters) making it the best suction lift PD pump available.Pro Cav pumps can pull the same suction lift as long as they are “wetted” or “primed.” If they attempt to pull a 29’ “dry” suction lift they will most likely run dry and ruin the rotor and stator.
11Peristaltic Pump Features & Benefits Reversible.Since there are no sealing devices required for a hose or tubing pump, they can be run in either direction.Reversing a pump can be an effective way to clear suction line blockages.Caution: before reversing a hose pump make sure that all components on the suction side of the pump are correctly sized for pressure.
12Peristaltic Pump Features & Benefits Low maintenance costs.The only repair parts required for peristaltic pumps are hoses or tubes. (NOTE: Shoe pumps also require replacement lubricant.)A typical hose/tube replacement takes less than 2 hours and the pump does not need to be removed for service.Most replacement tubes/hoses cost less than 10% of the purchase price of the pump!Example: A NR hose for a 50mm DulcoFlex pump is $748 list price. A Lobeline rotary lobe pump for the same flow rate would cost approximately $4500-$5000 to replace lobes and mechanical seals.
13Peristaltic Pump Features & Benefits Run DrySome PD pumps cannot run dry or risk catastrophic failure.Hose pumps are totally capable of running dry for an undetermined amount of time.The peristaltic hose pump can also handle fluids with air entrained or gases.In the WWTP world “run dry” is an ever present phenomena! When a run dry condition occurs with a pro cav pump the owner has about 30 seconds to one minute to either introduce fluid or shut the pump down before catastrophic failure occurs. Rubber and metal are not all that compatible without lubricity! Lobe pumps have a similar issue but you get a little bit more time to catch the run dry. The lack of cooling provided by the fluid allows the rubber lobes to heat up and swell. After about 20 minutes they can freeze a shaft.
14Peristaltic Pump Features & Benefits Gentle pumping action.Since hose pumps turn at slow speeds, the product is gently pushed through the hose with minimal turbulence.The hose pump is one of the best pump technologies available for minimizing damage to shear sensitive materials such as water based paints and flocculants.As great a product the hose pump is for shear sensitive materials, it is not often the “cheapest” technology. Too many very small inexpensive pumps that provide “OK” protection against shearing.
15Peristaltic Pump Features & Benefits Abrasion resistant.Hose life is NOT related to a products abrasive qualities.Due to the slow speeds and gentle pumping action the hose pump is capable of pumping some of the more abrasive liquids such as ink, sludge, and TiO2Big misconception in the industry. Because of the very slow speeds (typically under 30 rpm) there is minimal turbulence created by the gentle pumping action. Even with materials like sand for making sandpaper the abrasion factor is minimal with regards to wear life of the hose.
16Peristaltic Pump Features & Benefits No slip.Slip as defined is “the action of the positive displacement pump to allow some of the pumped liquid to be forced back into the cavity which is now filling with product.”Hose pumps are very close to being 100% volumetric efficient as slip is virtually eliminated by the complete compression of the hose.Remember that the volumetric efficiency is high when the hose/tube is new. As the hose wears, efficiency can decline as well. The problem is that the hose/tube doesn’t reform to it’s original shape which causes a performance drop. This drop is minimal and in all fairness is rarely noticeable.
18Peristaltic Pump Limitations There are a limited amount of elastomeric materials available for hose manufacturing. Inevitably there are some chemicals that hose pumps will not be able to be used for.Example: Toluene is not compatible with any rubber products associated with hose pumps.Sizing. Compared to other PD pump technologies, hose pumps have a large footprint.Only NR, NRB, EPDM and Hypalon hose material available to everyone.Peristaltic pumps are not only wide, they can be tall as well. Very difficult to meet any “flange to flange” retrofits.
19Peristaltic Pump Limitations Maximum flow rates typically are around 230 gpms.Temperature is restricted based on hose selection. The highest temperature condition is 210º F.There are pressure limitations based on pump speed. The faster the pump speed the lower the output pressure. Maximum pressure for DulcoFlex hose pumps is approximately 232 psi.NOTE: Maximum flow rate only good to about 225 gpm and this is with water! On a sludge application we can get about 160 gpms max.Temperature is limited by the hose manufacturer. All hose have a max temp rating of 175º F EXCEPT EPDM. It can go to 210º F.A DFD25 can hit 232psi as long as the speed is under 65 rpm. At 66 rpm the pressure rating drops to 145psi.
20Peristaltic Pump Limitations PulsationAll peristaltic pumps pulsate. This pulsation can affect sensitive in-line equipment such as flow meters and can cause excessive vibration in pipe lines.It is recommended that a pulsation dampening device be installed near the pump discharge.NOTE: most applications do not require a pulsation dampener on the suction side of the pump. However, on a suction lift application you would want to add a pulsation dampener. It will act as an accumulator and help the hose/tube reconstitute its original shape much easier.
22Roller versus Shoe Technology SLIDING SHOE TECHNOLOGYA set of fixed shoes slide over the surface of the hose causing it to compress the hose twice per revolution.Since the compression causes friction heat, the chamber is filled with a glycerin based food grade lubricant.
23Roller versus Shoe Technology ROLLER TECHNOLOGYRollers are mounted on permanently greased bearings.This allows the rotor to rotate smoothly during compression.The hose and outer roller surface are lubricated with silicon grease which reduces friction creating a lower starting torque, lower operating torque and less mechanical stress on the hose.
24Roller versus Shoe Technology Because of reduced hose stress, roller pumps can increase hose life by 30% over shoe compression pump hose life!Because of reduced torque, the roller pumps typically consume less HP.Roller technology is limited to 116 psi (8 bar) operating pressures. Shoe technology is suitable for operating pressures to 232 psi (16 bar ).
25Roller versus Shoe Technology Shoe pumps have a difficult time maintaining system pressure when operated below 3 rpms. However, a similarly sized roller pumps can maintain system requirements at speeds below 1 rpm!
27Hose Life Factors affecting hose life: Speed Temperature Process chemicalDischarge pressureSuction conditions
28Hose LifeSPEED KILLS!The single biggest impact on a hoses life is speed.With a hose life expectation of 10,000,000 restitutions before performance decline, you can see how the proper selection of the pumps speed is so critical.10,000,000 / 2 / pump rpm / 60 = approximate hose life.10,000,000 / 2 / 40 / 60 = 2083 hrs.10,000,000 / 2 / 30 / 60 = 2778 hrs.By selecting a pump 10 rpms slower, the hose life expectation increases by 25%!!!
30Hose LifeTemperatureHigher operating temperatures can cause the hoses to swell.This makes it more difficult to compress the hoses.DulcoFlex hoses are limited to 175º F on the NR, NBR and Hypalon.The EPDM hose has a temperature limit of 210º F
31Hose Life Process Fluid Peristaltic pumps have a limited availability of hose materials.Selecting the wrong material can cause premature failure of the hose/tube.For example:A fluid containing oils or fats/greases is not compatible with natural rubber. NBR would be the hose of choice.There are numerous chemical compatibility charts available to help select the correct hose material.
32Hose Life Suction Conditions Discharge Pressure Extremely high suction lifts can cause premature wearing of a hose.At greater lifts, the hose has a hard time restoring itself to it’s original shape.If the hose does not reconstitute itself back to it’s original shape, there is a reduction in the flow.A vacuum device can be installed to help the hose reclaim its original shape.Discharge PressureExtremely high discharge pressures make it very difficult for the roller or shoe to completely compress the hose.Slip can increase causing a decline in performance
33Hose LifeDulcoFlex reinforced hoses are manufactured to very specific engineered tolerances.The nylon reinforcement is hand wrapped assuring good quality control.The frequency of the wrap is also important.Increasing the frequency of the wrap extends hose life.
34Hose Life DulcoFlex hose. Competitors hose. Less frequency of reinforcementsDulcoFlex hose.More frequency of reinforcements – longer life!Frequency is the not the number of layers but the number of nylon reinforcements used per layer. The more reinforcement per layer means the longer the hose will maintain shape and pressure. The competitor hose is a WMB.
35DulcoFlex reinforced hose available in: Hose LifeDulcoFlex reinforced hose available in:Natural Rubber (175º F max)Nitrile Buna Rubber (FDA approved) (175º F max)EPDM (175º F max)Hypalon (175º F max)DulcoFlex tubing available in:Norprene (30 psi max)Tygon (30 psi max)
43Hose ConnectionThe majority of hose leaks occur closest to the discharge connection.The hose acts like a small “accordion” and because the hose is under system pressure at this point – most failures occur there.
44Hose ConnectionSeveral hose pump manufacturers have “external” hose connections. External hose failures can create environmental and safety hazards.WMB and Abaque use external hose clamps.
45Introducing the DulcoFlex Disaster Proof Connections. DulcoFlex FeaturesIntroducing the DulcoFlexDisaster Proof Connections.The flange housing is cast right into the pump.A beveled “C” clamp is attached to the hose.The insert is installed into the hose.The flange assembly is then attached which closes the “C” clamp firmly around the hose.Any leaks are now contained within the pump.
46DulcoFlex Features Heat dissipation Shoe compression pumps create a tremendous amount of heat.As we have learned, heat can affect hose life (shorten).DulcoFlex has designed our pumps to maximize heat dissipation.Heat sync tabs have been cast into the housings of our pumps.Keeping the hoses cool helps extend their life.
48Applications Industrial Markets Mining Chemical Pulp & Paper Food CeramicCosmeticsSlaughter houses (blood)Breweries/WineriesFishIndustrial wastewater
49PD Pump Comparison Feature Pro Cav Lobe Double Disc Piston Hose Flow 2000 gpm600 gpm550 gpm230 gpmPressure1500 psi150 psi40 psi130 psi230 psiSuction liftExcellentOK to PoorOKShaft sealMech/packBall checksNoneRun dryPoorLimitedGoodPump air entrained fluidVolumetricEfficiencyEase of repairBAD!Repair costFlow rates Hose pumps are lowestThe only PD pump with pressure issues is the double disc pump (Penn Valley). Most wastewater applications tend to be under 30 psiLobe pumps advertise high suction lifts but reality is because of the amount of slip engineered into the product they really can’t lift higher than about 12-15’.Most PD pumps are very good with volumetric efficiencies. A pro cav would give a hose pump the closest competition for efficiencies. However, just like a hose pump as soon as there is noticeable wear the efficiency declines.For repair costs only the Double Disc pumps are on the same level playing field as the hose pumps. All other PD pumps have extremely high repair costs associated with them.Pump pricing is a comparison of ONLY the 5 PD pumps listed. Pro cavs and lobe pumps under 150 gpms are very inexpensive. However, once they start getting into 200 gpms and higher they are very expensive. The worst are piston pumps like Komline Sanderson and Carter Pumps. Very expensive to purchase and to repair.
50DulcoFlex peristaltic pumps: SummaryDulcoFlex peristaltic pumps:Low maintenanceGreat suction lift capabilitySeal-less designReversibleAbrasion resistantAccurate dosing/meteringDisaster proof hose connections21 different models availableFlows to 225 gpmPressures to 230 psi
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