Challenge
ATEX compliance plus enhanced performance for AODD pumps

As a leader in air-operated double diaphragm pumps, Versa-Matic markets its products around the world - including Europe, where the 2003 ATEX Directive 94/9/EC mandates technical requirements for equipment intended for use in potentially explosive environments. ATEX is designed to reduce the risk of explosion from build-up and discharge of static electricity in such industries as mining, petrochemical processing and flour-milling.

Versa-Matic initially used metal parts in its pumps, but subsequently converted to a reinforced thermoplastic material which offered structural, thermal and corrosion resistance performance while allowing the design and manufacturing benefits of injection molding. However, while the thermoplastic design met all of these basic performance requirements it did not meet the requirement of ATEX 94/9/EC that mandates it has to be self grounding. This is a governing standard throughout Europe in demanding environments like ore and petrochemical processing; food, beverage and pharmaceutical manufacturing; and wastewater treatment where fire and explosions from electrostatic discharge are a health and safety risk.

“We pride ourselves in manufacturing the best AODD pumps in the world,” said Erik Dillen, Continuous Product Improvement (CPI) Engineer for Versa-Matic. “Compliance with ATEX was essential, but we also wanted a plastic material that could deliver additional benefits to our customers, including high performance and durability. And we had another challenge - upgrading the material without retooling.”

Solution
Electrically conductive LNP Stat-Kon specialty compounds

Versa-Matic contacted SABIC Innovative Plastics for assistance in finding the best materials for its proposed line of ATEX-compliant AODD pumps. Specifically, the company was interested in upgrading the existing resin used in the water chamber, manifold, center and valve components for a product line offering inlet/outlet port sizes ranging from 3/8 in. to 3 in.

To meet the requirements of the ATEX directive, Versa-Matic selected two of SABIC Innovative Plastics’ electrically conductive, carbon fiber-reinforced LNP Stat-Kon specialty compounds for the water chamber, manifold and center, and valve. These thermoplastic composites inhibit static charge from building up and prevent discharge that would create a safety hazard. Any electrostatic discharge that might occur is conducted and dissipated throughout the composite matrix or directed to ground if the pump is installed with a natural path to ground.

In addition, LNP Stat-Kon compounds met Versa-Matic’s other stringent performance requirements. First, the carbon fiber reinforcement adds stiffness and strength required for high-volume, high-speed pumping operations. Second, the LNP Stat-Kon compounds offer excellent resistance to chemical attack, allowing them to withstand various types of liquids, powders and slurries pumped in different industries. Additionally, the LNP compounds chosen allow the pumps to be rated for use in elevated  temperature applications operating up to 79 C.

According to Jim Fagan, SABIC Innovative Plastics Product Manager, “Because we offer such a wide range of compounds for electrostatic discharge protection, Versa Matic was able to select the two LNP Stat-Kon grades to address every one of their needs - regulatory compliance, performance and processing in their existing molds. Further, we provided development support to Versa-Matic and its molders on material selection and processing trials, as well as support in helping Versa-Matic develop an internal material specification.”

Benefits
Compliance with regulatory and corporate standards for safety and performance

By replacing its previous resin with LNP Stat-Kon electrically conductive specialty compounds, Versa-Matic was able to design and launch a new line of ATEX-compliant AODD pumps. And by avoiding traditional metal parts or grounding straps, the company was able to reduce costs and weight for a competitive advantage.

“The composites allowed us to design a new line of AODD pumps that can be competitively marketed in Europe for a wide range of industrial applications,” said Dillen. “SABIC Innovative Plastics not only assisted us in helping to address our compliance challenge, but its LNP Stat-Kon specialty compounds also delivered the high performance, durability and moldability we needed. Engaging SABIC Innovative Plastics in our development process enabled us to identify and validate the right products quickly and efficiently- saving us time, expense and effort.”

Details at
versamatic.com