When seals fail, systems fail. This case study shows how Thomson Process and Viking Pump delivered a reliable, low-maintenance solution for fuel dye injection under tough ATEX conditions.
Client: A customer in Ireland engaged in the importation and distribution of bulk fuels, incorporating traceable fuel dyes to meet customs and taxation regulations.
Industry: Fuel distribution and logistics.
Challenge: Replace outdated pump systems to improve reliability and efficiency under challenging operational conditions.
Background
In 2022, a client faced persistent challenges with their fuel additive injection system. This operation is critical for adding dyes to bulk fuel shipments, ensuring compliance with strict regulatory requirements for traceability.
The existing competitor internal gear pumps struggled under harsh operating conditions. The additives contained toluene, a strong solvent, and abrasive crystalline solids. These components accelerated wear on mechanical seals and Viton elastomers, leading to frequent leaks, breakdowns, and costly maintenance.
The system needed to maintain a steady 10-bar pressure (145 psi) to ensure proper injector function, while also delivering a constant flow rate. Space constraints around the pumps made maintenance access difficult, and because the pumps operated in an ATEX area, safety standards were stringent. Reliability was paramount: pumps could remain untouched for long periods yet had to perform flawlessly when called upon.
The Journey
Our assessment confirmed the limitations of the internal gear pumps in this duty. To address the client’s requirements, we recommended transitioning to external spur gear pumps, designed with tight clearances to handle low-viscosity fluids at high pressure.
We also integrated MagDrive technology — replacing mechanical seals with a magnetic coupling. By eliminating the seals entirely, we removed the primary cause of leaks and maintenance intervention.
To withstand the aggressive chemistry, we specified PTFE seals, offering superior resistance and long service life. Finally, we implemented a pressure-sustaining valve to stabilise system pressure, ensuring consistent 10-bar operation for accurate and reliable dye injection.
Solution
By switching to external spur gear pumps, the client achieved improved reliability in handling thin fuel additives under pressure. MagDrive coupling eliminated the weak point of seals, removing the main source of leaks and downtime.
The upgraded design also addressed the abrasive nature of the crystalline solids in the dyes, ensuring minimal component wear. With limited space for maintenance access, the pumps’ ability to operate for long periods without intervention was a critical advantage.
Outcome
Since the upgrade, the system has delivered exceptional reliability. The MagDrive pumps have run for extended periods with minimal maintenance, providing consistent performance and durability under harsh conditions.
The result: reduced operational downtime, improved safety in the ATEX environment, and a calmer maintenance schedule.
This success story underscores the value of combining the right technology with close collaboration. Working alongside the client’s team, we implemented a tailored solution that solved the problem at its source and delivered lasting results.
Key Takeaways
- Reliability: MagDrive pumps delivered consistent uptime with minimal maintenance.
- Technical innovation: External spur gear + MagDrive addressed low-viscosity and high-pressure challenges.
- Harsh conditions: Robust design tolerates toluene and abrasive solids.
- Space efficiency: Compact, low-maintenance design suited to tight ATEX environments.
👉 At Thomson Process, we design and deliver engineered solutions that keep critical processes running. If you’re facing similar challenges with chemical dosing, fuel additives, or ATEX applications, get in touch with our team to discuss how we can help.
