WHAT MAKES LOW ENERGY AIR PUMP DIFFERENT
Tapflo UK Ltd. are at the forefront of the energy saving revolution and have developed the LEAP (Low Energy Air Pump) technology. Airflow through the pump is controlled in a fundamentally different principle to vastly reduce the air consumption of their diaphragm pumps from the industry standard of 1.2 bar to 0.2 Bar!
LEAP® or ‘Low Energy Air Pump’ is a patented technology used in Air Operated Diaphragm Pumps to reduce the operating air pressure by reducing internal losses and friction found in conventional Air Operated Diaphragm pumps. It can be retro-fitted to any Tapflo, Dellmeco & Almatec Air Operated Diaphragm Pump or supplied as a complete pump for fresh applications.
LEAP® was derived from a specialist pump designed by Tapflo (UK) to pump ammonia solution at 4LPM at 40bar. The technology utilised in HODD or ‘Hydraulically Operated Double Diaphragm’ pump was transfered to a pneumatic pump giving exceptional performance, and the birth to LEAP®
Featues and Benefits of Tapflo Low Energy Air Pump
- Available on the complete range of Tapflo Air Operated Diaphragm Pumps as well as Dellmeco & Almatec
- Retro-fittable: to switch an existing Tapflo, Dellmeco or Almatec Air Operated Diaphragm Pump over to LEAP only the centre section needs replacing.
- Ultra Low starting pressure2 Bar (3psi)
- Reduced energy consumption saving up to 70%
- Impossible to stall (mid-port)
- 24vdc starting signal (2.3w/1w) & Dry contact (VFC) feedback on completed strokes – provides control & feedback to the operator for preventive maintenance as well as performance monitoring such as:
- Batch dispensing: Simply counting the strokes of the diaphragms and stopping the pump after the required volume has been dispensed.
- Dry Running: By analysing the frequency of the pulses you can monitor whether the pump is dry running or not. When the pump starts to dry run the frequency of the pulses will increase.
- Dead Heading: When the frequency of the pulses slows down or stops this means that the pump has deadheaded, indicating closed valve operation or a blockage in the pipework.
- Flow Monitoring: Counting the frequency of the pulses can also be used to monitor the flow rate of the media in the process. The diaphragms displace a set amount per stroke therefore by multiplying the strokes by the volume displaced per stroke provides an accurate indication of flow. Or indeed, in the case of one of our customers, wiring in a coreolis flow meter with pulse feedback into their system to provide real-time monitoring of flow to within an even greater degree of accuracy. Coreolis Flow Meters are NEVER used with diaphragm pumps as they are susceptible to pulsing flow. This is testament to the ability of the LEAP Pump to reduce the pulsing effect usually associated with traditional diaphragm pumps.
- Easy to maintain – Air Valve can be replaced in under 2 minutes, pump disassembly isn’t required!
- Reduced pulsation – negates need for a pulsation dampener in many instances!
- EP Mode for high pressure applications and start control: As standard the unit is supplied with an internal pilot signal, however, should the unit be required to be used in a high pressure application, in excess of 10 bar, i.e. Filter Press applications, the unit can be easily modified to use a lower pressure external pilot.
- One seal design – reduced frictional losses
- Noise reduction – lower air pressures reduces the noise of the pump
- Control simplification – No need for an external pneumatic solenoid valve, reducing costs and simplifying control
- Improved Life of main Air Valve: Tapflo have developed their own air valve for use with the LEAP technology using a lapped spool and sleeve construction. This provides a life expectancy in excess of 200 million cycles!
For more information and a case example of where our Low Energy Air Pump (LEAP) has been integrated into a production line with control and monitoring from a central control system, visit our case studies section. The valve is also balanced to prevent any issues associated with high pressure applications.
Reduced Air Consumption
Graph showing fluid flow against air pressure required
The graph below shows fluid flow against the air pressure required when comparing a standard Air Operated Diaphragm Pump against Tapflo’s Low Energy Air Pump (LEAP). As you can see, at 0.5 bar air pressure, the LEAP pump was able to produce approx. 27.5 l/min whereas the standard pump didn’t even start operating until it was supplied with 1.1 bar air pressure, and only produced 5 l/min. This demonstrates that standard Air Operated Diaphragm Pumps require a lot of energy to simply overcome the resistance within the pump. The energy required to do this is a direct correlation to the pressure you have to put in. By reducing the air pressure required to operate you can significantly reduce the operating costs of the pump. To put this into monetary terms, Tapflo customer required a 2” pump to run continuously for 5 days a week, 48 weeks / year, producing 150 l/min @ 1 Bar operating pressure. Based on the British Compressed Air Society figures of between £0.01 to £0.03 to produce 1000 Litres of compressed air, a standard pump would cost an average of £1843.20 / year. By converting to the LEAP technology, the customer would save £652.64 / year per pump!
|Spare Parts, TC50, 70 & 80
|Spare Parts, TC100, 120, 125
|Spare Parts, TC200, 220, 225
|Spare Parts, TC400, 420, 425
Recommended Spares for Stocking for the Low Energy Air Pump
Even during normal operating conditions some parts of the pump will be subject to wear & tear. In order to avoid expensive breakdowns we recommend having a few spare parts in stock.
Depending on the severity of the operation and the importance of assuring continuous operation we offer three different spare part KITS, please check full PE & PTFE, Metal, Sanitary IOM manuals* for further instructions. Please keep in mind that Low Energy Air Pump KIT AIR differs from standard PE & PTFE, Metal or Sanitary pump*.
NOTE! Even though the Control Module [97E] is not a subject to wear, remember to replace it in case of leakage through muffler.
*depends on the product series
|TC50, 70 & 80|
|KIT AIR||16E||Complete Diaphragm Shaft||1|
|18||O-Ring Set (Inlet / Outlet)||4|
|61E||Complete Air Valve||1|
|TC100 – 425|
|KIT LIQUID||18||O-Ring Set (Inlet / Outlet)||4|
|16E||Complete Diaphragm Shaft||1|
|1211E||Back Plate Square O-Ring||2|
|1212E||Back Plate O-Ring||4|
|1213E||Back Plate O-Ring||8|
|1214E||Back Plate O-Ring||4|
|361E||Shaft Cut Wear Ring||2|
|362E||Shaft Wear Ring (back up for 36E)||1|
|61E||Complete Air Valve||1|
Tapflo Low Energy Air Pump has been recognised by the PPMA Group Industry Awards for the category ‘Innovative Processing Systems’.
For its innovative technology, LEAP was granted a Highly Commended recognition.
Download the Entry for the PPMA Awards 2017