JSW Nandyal — Antlia Engineering Works site visit
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During our visit to the JSW – Nandyal site, we observed multiple operational and performance-related issues in the existing fluid handling systems used for pharmaceutical waste transfer.
Below are the observations made during the site visit along with the identified issues and possible solutions discussed with the site team.
Two AODD pumps of Company A are installed for unloading pharmaceutical waste. The following issues were observed:
Low quality of main diaphragms (pure PTFE) and flexibility issues are causing lower output and quick rupture of the diaphragms.
One of the AOD pumps is facing an air valve issue where the pump skips strokes during startup and stabilizes only after a few strokes. The issue may be related to the piston, spool, or air valve design.
Two diaphragm pumps of Company A are installed for transferring pharmaceutical waste to another tank.
The pumps appear to be operating in good condition currently.
One double diaphragm pump of Company B is installed at the ground level and one aod pump of Company A is installed at the 2nd floor.
The existing aodd pump is not operating at the required efficiency, due to which a second pump has been installed inline on the 2nd floor for boosting purposes.
Instead of using two pumps inline, a more efficient pump with higher capacity and flow can be used to improve the system. Currently, if either of the diaphragm pumps fails, the entire system becomes affected.
The design of the pumps from Company A and Company B appears to be identical. Both suppliers may be sourcing from the same reseller, resulting in lower quality PTFE products.
Two air operated double diaphragm pumps of Company C were previously installed (currently not present at the site) for transferring waste from the ground level to the 2nd floor.
The application includes:
Due to the high back pressure caused by multiple bends and long displacement, diaphragms are likely to rupture repeatedly.
AODD pumps are generally not suitable for such long-run transfer applications.
This site visit highlighted how diaphragm quality, transfer distance, piping layout, air valve performance, and operating conditions directly affect long-term reliability and efficiency in industrial fluid handling applications.
Our engineers at Antlia Engineering Works, Mumbai provide on-site visits, pump selection, and after-sales technical support across India.
Get in Touch Call +91 9819395995Low quality PTFE diaphragms lack the flexibility required for continuous reciprocating action. Poor quality PTFE causes lower output and quick rupture. Replacing with NXT grade PTFE diaphragms — which offer higher quality and better flexibility — significantly extends diaphragm life.
Stroke skipping during startup is typically caused by a worn or damaged air valve assembly — specifically issues with the piston, spool, or air valve design. The pump stabilises after a few strokes as air pressure builds. The solution is to replace the pump or change the air valve assembly.
Running two pumps inline creates a single point of failure — if either pump fails, the entire system is affected. A better solution is to replace both with a single higher capacity AODD pump that meets the required flow rate, reducing complexity and improving system reliability.
AODD pumps are generally not suitable for long-run applications with multiple 90-degree bends and high vertical lift due to high back pressure causing repeated diaphragm rupture. A peristaltic pump or hose pump — a positive displacement pump operated electrically — is the recommended solution for such applications.