Fueling Reliability: How Viking Pump’s Mag Drive Solution Transformed Dye Injection for Ireland Fuel Distributor

In the world of fuel distribution, precision and reliability aren’t just nice-to-haves—they’re essential. That’s especially true when you're dealing with fuel additives like traceable dyes, which help meet strict customs and taxation regulations. One fuel distributor in Ireland found this out the hard way when their dye injection system started causing more headaches than solutions.

The Problem: Leaks, Wear, and Downtime

Back in 2022, this customer was facing serious issues with their fuel additive injection system. The system’s job was to add dyes to bulk fuel shipments, making them traceable for regulatory compliance. But the existing competitor internal gear pumps weren’t up to the task.

Why? The additives contained toluene, a strong solvent, and abrasive crystalline solids. These harsh ingredients were wearing down the pumps’ mechanical seals and other elastomers. The result? Leaks, breakdowns, and costly maintenance.

To make matters worse, the system needed to maintain a steady 10-bar pressure (about 145 psi) to ensure the injectors worked properly. It also had to deliver a constant flow rate, which is tricky when your equipment keeps failing. And because the pumps were installed in tight spaces and operated in an ATEX area—a zone with potentially explosive atmospheres—maintenance access was limited and safety requirements were strict.

The Challenge: Find a Better Pump Solution

The customer needed a pump system that could:

• Handle aggressive chemicals and abrasive solids
• Maintain high pressure and consistent flow
• Operate reliably with minimal maintenance
• Meet safety standards for explosive environments

The Solution: A Smarter, Safer Pump System

Enter Viking Pump and their distributor, Thomson Process Equipment & Engineering Ltd. After assessing the situation, they recommended switching to external gear pumps These pumps have extremely tight clearances, making them ideal for low-viscosity fluids (thin liquids like fuel additives) and gears that are supported on both sides, allowing for higher pressure capability.

But the real game-changer was the integration of Mag Drive technology. Instead of using mechanical seals, these pumps use a magnetic coupling—a method where magnets transfer torque through a sealed barrier. This eliminates the main source of leaks and drastically reduces maintenance.

To further boost durability, the team used PTFE elastomers which are highly resistant to chemicals. They also added a pressure-sustaining valve to the system to maintain overall system pressure, ensuring the dye injection process runs smoothly even when conditions fluctuate.

The Result: Reliable Performance with Less Hassle

Thanks to these upgrades, the distributor now enjoys:

• A leak-free system that handles tough additives with ease
• Consistent pressure and flow for accurate dye injection
• Minimal wear and tear, even with abrasive solids
• Reliable operation in tight, hazardous spaces without frequent maintenance

The Viking Pump SG805 Series™ Mag Drive skid proved to be the perfect fit—literally and functionally.

Why It Matters

This story isn’t just about pumps—it’s about solving real-world problems with engineered solutions. Whether you're in fuel distribution or any other industry dealing with harsh chemicals and tight regulations, choosing the right equipment can make all the difference.

If you're facing similar challenges, it might be time to rethink your pump strategy. Sometimes, a small change can lead to big improvements.