Water ring vacuum pump
Contents
1. BALL so o so o m BEARING BRACKET CAST IRON CAST IRON CAST IRON Baca 2 CASTSTEEL CASTSTEEL 1 CASTRON CASTRON CASTRON _ ro NP STUDFORPUMP MS MS 55 12 365 LONG forvws 751l 16 420 LONG forvws 100II vws 150ll vws 2001l LOCK NUT 1 o omo o so mo _ 40 mm X 1 5 mmTHK 8 SUBJECT TO CHANGE WITHOUT ER NOTICE PPISYSTEMS VWS Il TWO STAGE PUMPS SER 11 LIST ACCESSORIES Vacuum 0 to 760 of direct mounting Coupling Set Tyre Coupling Ball Valve on off Valve otop cock valve water regulating valve Common base frame for pump and motor Matching flange Fitted with pump Water strainer Brass for water line OPTIONAL ACCESSORIES 1 Non return valve 2 Coupling guard 3 Foundation bolt 4 Silencer Carefully remove the pump from packing cartoon and examine for transportation damage Check that all accessories are included if you fin missing any item consult to our works PPISYSTEMS VWS II TWO STAGE PUMPS 12 RECOMMENDED SPARES FOR ONE VACUUM PUMP SR NO PARTNAME _ 2 Mechanical Seal 2 Bearing drive amp non drive 6306 for VWS 50 75 Two Stage gt Bearing drive 8 non drive 6308 for VWS 100 150 200 Two Stage 2 Lock Nut for Rotor 5 6 Spacer te 72. w HARD FOUNDATION mS iwa VACUUM GAUGE 06mm OF Ho amp CASING SECOND STAGE LX CASING FIRST STAGE SR NO DESCRIPTION QTY SYSTEMS VWS II TWO STAGE PUMPS OUR OF OTHER PRODUCT WATER RING VACUUM PUMP y WATER RING VACUUM PUMP IN enis GLE CO TWO STAGE VACUUM PUMP TE OE TU TE NT PPI SYSTEMS Green House Phase 1 G I D C Estate Vatwa Ahmedabad 382445 India Phone 91 79 2583 2273 2583 2274 2583 5698 Fax 91 79 2583 0578 E Mail sales ppipumps com Website www ppipumps com BRANCHES SALES OFFICE e NEW DELHI PH 093129 94234 3090 7842 e MUMBAI PH 093225 48175 2562 5473 e CHENNAI PH 093801 99659 2361126 e HYDERABAD PH 098480 38130 236160061 INDORE 098270 70528 593060 668 e KOLKATA 098304 62669 26512483 e U P PH 093193 93897 e BANGALORE PH 093798 67883 HARMEE 7 1 FH 079 2755 6742
3. OTHER PRODUCT 19 PPISYSTEMS VWS IL TWO STAGE PUMPS 5 CUSTOMER MODEL NO TYPE PUMP SR NO CAPACITY MAXIMUM VACUUM mm of Hg DUTY POINT CAPACITY DRIVE DETAILS Direct MOTOR SPEED 1440 RPM PUMP SPEED 1440 RPM FRAME SIZE OF ELE WATER REQUIRED L P M WATER PRESSURE 1 0 kg cm BEARING NO MANUFACTURING DATE INSTALLATION DATE COUPLING Tyre SIZE PPISY STEMS VWS II TWO STAGE PUMPS 1 SAFETY INSTRUCTION WARNING This operating manual gives basic instructions which are to be observed during installation operation and maintenance of the pump It is therefore imperative that this manual is read by the responsible personnel operator prior to installation and commissioning It is always to be kept available at the installation site WARNING DONOT CARRY OUT ANY MAINTENANCE WHILE THE PUMP IS CONNECTED TO THE MOTOR NEVERSTART OR STOP THE PUMP WITHOUT WATER NEVERINCREASE HEIGHT OF WATER OUTLET FROM PUMP SILENCER IT WILL ABSORBS MORE POWER amp TRIPPING OF ELECTRIC MOTOR ITIS ADVISABLE TO CHECK THE WATER HARDNESS AND IN CASE OF THIS EXCEED AND TOLERANCE LIMITS 50 to 150 PPM A PROPER PURIFICATION SYSTEM SHOULD BE PROVIDED INCASEOF CALCAREOUS WATER IT IS NECESSARY TO DISASSEMBLE FROM TIME TO TIME THE PUMP DESCALE IT DONOTLOOSE OR TIGHTEN BEARING COVER BOTLS WITHOUT ANY INSTRUCTION SAFETY INSTRUCTIONS RELEVAN
4. pump with diesel kerosene and leave it 24 hours Most probably pump will be free If not then Check for Mechanical Rubbing or Touching IF PUMP DOES NOT DEVELOP SUFFICIENT VACUUM Check the vacuum gauge against master gauge Check for back pressure and make sure that discharge line is open to the atmosphere Check amp see that outlet of silencer is not choked Check quantity of water Make sure it is as per given in manual Also check inlet water pressure which should be 1 0 kg m2 max IF PUMP MAKES NOISE If rattling continues to be heard at low vacuum open the pump and check for entry of foreign particle and also check for broken rotor blade because of that particles Check the alignment to rotor with the pump and distance between two coupling IF YOUR MOTOR IS OVERLOADED Check that pump turns free by hand when stationary Check excessive seal water quantity and pressure Check alignmentto motor with the pump and distance between two couplings 1 Dismantle pump and check for any internal damages or for scale formation Excessive scale formation can effect to the smooth operation of vacuum pump and overload the motor PPISYSTEMS VWS IL TWO STAGE PUMPS 10 MATERIAL OF CONSTRUCTION CONTROLDISC D SIDE BET N il CASTIRON 55 304 55 316 55 304 55 316 CONTROLDISC C SIDE BET N CASTIRON 55 304 55 316 55 304 55 316 ooo TWO STUFFINGEOX 2 CASTRON CASTRON 5308 SS 316 _
5. 2 PPISYSTEMS VWS II TWO STAGE PUMPS KCN 5 DRAWING 291519 3 OOO 5 909 09 A p TN en NE Ly l ER T L zu H mg PT m L He 10 RA TFE N NEAL WI a w gt WATER DRAIN lt JE t DRAIN E ANN 0 27 9665 JHA CLOCKWISE ROTATION FROM COUPLING END STUD FOR PUMP LOCKING WASHER I LOCKING NUT EES EUN ROTORNUTFORLOCKNGROTOR la COVER SSS BEARNG OO 15 BEARING COVER INNER SIDE C S KK SSS CONTROLOISCICSDE BETWARSTGSECONDROTOR 0 CONTROL DISC BETWFRSTGSECOND ROTOR O 6 CONTROL DISC DRIVE SIDE 2 USNGGEODSUEE VWS IL TWO STAGE PUMPS 7 o y 15 1 15 po 12 12 oo 12 1 15 1 12 _ 11 A DRAWING DISCHARGE FLANGE SUCTION FLANGE 2 4 WATER INLET PRESSURE NOTE 1 ITEM MARKED WITH IS NOT IN PPI SCOPE 2 DIRECTION OF ROTATION CLOCK WISE 9 SUCTION lt TT lt zs 2 T p d ESI
6. T FOR MAINTENANCE INSPECTION AND ASSEMBLY WORK Any work on the pump shall only be performed when it is at a standstill t is imperative that the procedure for shutting down the machine described in this manualis to be followed Pumps and pump units which convey hazardous media must be decontaminated On completion of work all safety and protective facilities must be reinstalled and made operative again Close the isolating valves at pump inlet outlet and seal water Let the pump cool down to ambient temperature if it has been handling hot fluid Adopt safety measures if the pump has been handling hazardous fluids UNAUTHORIZED ALTERATIONS AND PRODUCTION OF SPARE PARTS Any modifications may be made to the vacuum pump only after consultations with the manufacturer Using spare parts and accessories authorized by the manufacturer is in the interest of safety Use of other parts may exempt the manufacturer from any liability UNAUTHORIZED MODE OF OPERATION The reliability of the vacuum pump delivered will only be guaranteed if it is used in the manner intended and in accordance with the instructions of this manual The limit values specified in the data sheet must under no circumstances be exceeded SYSTEMS VWS II TWO STAGE PUMPS 2 LOCATION OF PARTS 2 4 97168 10 1 Base Frame Electric Motor Vacuum Gange Tyre Coupling 2 3 4 5 6 Ball valve 7 Stop Cock Water Regulating Valv
7. Two Stage Water Ring Vacuum Pump VWS Series INSTRUCTION amp OPERATION MANUAL PPI SYSTEMS ISO 9001 2008 CERTIFIED COMPANY Thank you for purchasing the RING VACUUM Before using the pump please read the operating instructions so you can easily install operateand maintain thepump This pump or this pump unit respectively may be mounted and put into Operation by qualified technical personnel only and these operating instructions and the effective regulations have strictly to be observed If you don t pay attention totheseoperating instructions 1 Danger may becreated for you and your colleagues 2 or thepump unit may bedamaged 3 The manufacturer is not liable for damages resulting from this non observance Pleasebeawareof your responsibility for your fellow men when working at the pump or thepump unit PPISYSTEMS VWS II TWO STAGE PUMPS CONTENTS DATA SHEET Page No 1 SAFETY INSTRUCTIONS WARNING 1 2 OF ITEMS 2 3 ERECTION amp INSTALLATION PROCEDURE 3 4 4 CONNECTION OF VACUUM PUMP 5 5 WORKING INSTRUCTION 6 6 PARTS INFORMATION 7 7 DISASSEMBLY AND ASSEMBLY FOR MAINTENANCE 8 11 8 TROUBLE SHOOTING PROBLEMS GAUSES AND SOLUTIONS 12 9 BEFORE YOU CALL SERVICE PERSONNEL 13 10 MATERIAL OF CONSTRUCTION 14 11 LIST OF ACCESSORIES 19 12 RECOMMENDED SPARES 16 CROSS SECTIONAL DRAWING 124 GENERAL ARRANGEMENT DRAWING 18 RANGE OF
8. WEEN BOTH COUPLING HALVES TYPE COUPLING COUPLING SIZE USED ON MODEL VWS 50 amp VWS 75 TWO STAGE VWS 100 amp VWS 160 TWO STAGE VWS 200 TWO STAGE MOUNTING OF THE PUMP AND INSTALLATION INTO THE PIPING SYSTEM On delivery suction and discharge branch as well as the service liquid connection are closed to prevent the entering of foreign bodies The Blind Rubber Packing to be removed only immediately before connecting the pipelines The weight of heavy pipelines must be supported in order to prevent distortions of the pump The pump has to be aligned with the pipelines The screws are to be tightened in the following order Tightening of the flange connections of suction and discharge line Fastening of the service liquid line Tightening of the pump feet and of the motor feet FINAL WORK The following final work must be carried out Check the tightness of the connecting flanges Check the easy running of the pump for that purpose turn the coupling PPISYSTEMS VWS IL TWO STAGE PUMPS 4 4 CONNECTIONS OF VACUUM PUMP PIPELINES Pay attention to the arrows at the pump pipe line indicating the flow direction The nominal widths of the pipelines must not be smaller than the nominal widths of the corresponding pump branches 1 Allpipelines must be cleaned prior to installation of the pump The pipelines must be supported in order to avoid distortions of the pump components danger of breaking of the pump c
9. control disk upward Center the central body on the control plate Insert the pre assembled shaft drive side upward and center control plate on to the central body Center the central body on to the control plate Center the pre assembled casing control disk first on the central body Tighten the tie bolts only manually Push on the shaft the spacer and the rotating parts of the mechanical seal Observe the correct sense of rotation of pumping screw clockwise Press Stationary seal ring of mechanical seal in the shaft sealing casing and fasten by the screws to casing Pay attention that the cast on the rear side of the shaft seal casing points toward the casing feet Center the bearing bracket on the casing in such a way that the drain opening points to the casing feet then tighten by the screws Press in the cleaned or new anti friction bearing Fasten the bearing covers and with the screws to the bearing bracket Turn the pump carefully by 180 so that the drive side points downward Push on the shaft the spacer and the rotating parts of the mechanical seals Observe the correct sense of rotation of pumping screw clockwise Press stationary seal ring of mechanical seal in the shaft sealing casing and fasten by the screws to casing Pay attention that the cast on the rear side of the shaft seal casing points toward the casing feet olip on the shaft the bearing cover and the thrower Center the bearing bracket on the casing in such a way tha
10. disassembly the pump especially observe that no toxic or aggressive media can escape from open lines Secure the shut off organs against unauthorized operations Drain the pump before the disassembly out of the plant After draining residuals of liquid will remain in the pump which must be removed by flushing the pump with a suitable liquid The electrical connections must be fixed or separated respectively only after removal of the corresponding fuse MAINTENANCE The pump requires only little maintenance However the following points must be observed Thebearings shall be lubricated after approximately 10 000 service hours mechanical seals do not require any maintenance With normal operation leakage s occur only after several 1000 service hours if parts subject to wear are used up Incase of risk of freezing the pump the liquid separator and the pipelines are to be drained if necessary the pump is to be preserved Ifthe pump is required to be storage for long time drain water completely by opening two plugs at the bottom of casing cover Fill the lubrication oil from suction flange Incase strongly calcareous water is used as service liquid the pump has to be opened at least in a period of six months in order to remove the calcareous scale deposits The calcareous deposits can be avoided if the service liquid is prepared with a suitable agent The measures to be taken depend on operation time and water quali
11. e 8 Inter Connecting Pipe 9 Suction 10 Dishcharge SYSTEMS VWS II TWO STAGE PUMPS ERES 3 ERECTION amp INSTALLATION PROCEDURE PROPER ERECTION IS VERY IMPORTANT FOR SMOOTH RUNNING amp LONG SERVICE OF THE PUMP REFER G A DWG 1 Prepare foundation as per drawing 2 Generally vacuum pump supplied with Common Base frame for Pump amp Motor amp Coupling set In this case pump side coupling is supplied duly fitted on pump You have to connect motor side coupling on your electric motor PROPER FOUNDATION Correct foundations and installations are essential to assure safe operation non compliance with the norms of correct foundation and installation could cause pump failures The pump must be installed on flat surface rigid enough to withstand its weight and suitable to withstand the loads cause by the motor mechanism and by the pump operation In order to avoid vibration or wear of the coupling it is necessary to keep a correct alignment during continuos operation conditions MOUNTING OF COUPLING When assembling pump and motor both shafts must be centrally to each other and be easily turntable The distance between both coupling halves shall have the specified measurement ref Figure 1 TYRE COUPLING T5 25 VWS 50875 TWO STAGE T6 M 30MM VWS 100 150 TWO STAGE T7 42 VWS 200 250 TWO STAGE PPISYSTEMS VWS IL TWO STAGE PUMPS oUFIG 5 1 MEASUREMENT BE SET BET
12. ever start pump without water Always start the water first then pump 3 Regulate the quantity of water supply as per pump data sheet by means of plug or stop cock Excessive water quantity is also dangerous and may overload the motor 4 Check the temperature rise of bearing housing at regular intervals of 15 minutes during the first two hours of operation 5 If the temperature does not stabilizes below 65 degree centigrade stop the pump and investigate the problem STOPPING 1 Always stopthe pump first and then the water supply 2 Close the water line ball valve without disturbing the cock valve STORAGE If the pump is required to be storage for long time drain water completely by opening two plugs at the bottom of casing cover Fill the lubrication oil from suction flange To avoid rust deposition inside the pump PPISYSTEMS VWS II TWO STAGE PUMPS 6 PARTS INFORMATION Casing 1st Stage Casing 2nd Stage Cover Rotor 1st Stage Rotor 2nd Stage S haft C Side Control Plate NDE D Side Control Plate DE C Side Control Plate with D Side Control Plate Between Rotor SETS Bearing Bracket Stuffing Box Bearing Cover inner Drive Non Drive End seamy Lock nut for Rotor Inter Connection pipe Tyre Coupling Mech Seal Rotor with Shaft PPI SYSTEMS VWS II TWO STAGE PUMPS 1 DISASSEMBLY amp ASSEMBLY FOR MAINTENANCE BEFORE STARTING THE PUMP DISASSEMBLE ENSURE THE FOLLOWING THINGS When assembly and
13. omponents The suction discharge and service liquid lines must be as short as possible and their cross section must be as least as the corresponding pump connections For long pipelines larger cross sections are required identify first locations and dimensions of all connections required to interconnected the pump with the installation then proceed with the actual piping SUCTION LINE A non return valve should be installed in the suction line It prevents back flow of gas and liquid in the suction piping when the pump stopped If the pump shall be started up or stopped with closed shutoff element e g Valve in the suction line cavitation occurs too DISCHARGE LINE Thedischarge line must not be led more than 1m vertically or diagonally upwards If a shutoff element is installed in the discharge line behind the liquid separator it must be ensured that the pump cannot be put into operation while this shutoff elementis closed SEAL WATER LINE For a good operation the watering vacuum pumps must be supplied with a seal water which is clean non abrasive and of any solids The service seal water should not exceed 30 31 degree centigrade and the gas handled should be maximum 90 degree centigrade PPISYSTEMS VWS IL TWO STAGE PUMPS 5 WORKING INSTRUCTION STARTING 1 Turn shaft by hand to ensure that pump runs freely 2 Start electric motor see the direction of rotation It should be clockwise looking from the coupling side N
14. ry out a hydrostatic pressure test with 4 kg cm2 hydraulic test Drain pump Carry out aleakage test with foaming agents PPISYSTEMS VWS IL TWO STAGE PUMPS 8 TROUBLE SHOOTING PROBLEMS CAUSES amp SOLUTIONS 000 rotation connection phase consistency 2 A justthe coolingwaterflm 5 Coupling misalignment 6 Faulybearing 7 cavitation Open the anti cavitation valve orsetthe relief valve to a lower vacuum 8 Highsealwaterflow Reduce the seal water flow adjustthe by pass valve 9 Highback pressure Checkthe discharge line forobstructions orhigh friction losses reduce the back pressure to 0 1 bar 10 Wrong pump motorassembly Verify thatthe base surface is level and thatall pump feetare resting onthe surface add spacer Check flushing liquid temperature flow and pressure i Foreign paries pur 17 Lowsuction pressure Open the vacuum regulating valve and orthe vacuum relief valve Disassemble and repairthe pump 24 Excessive liquid flow through suction line Reduce the flow through the pump suction install a centrifugal seperator cyclone before the pump 25 Instrumentation outof calibration Check working characteristics replace if required SYSTEMS VWS Il TWO STAGE PUMPS 12 9 BEFORE YOU CALL SERVICE PERSONNEL READ instruction manual carefully and thoroughly ALWAYS start water first and then pump NEVER start pump without water IF PUMP GOT JAMMED First fill
15. t the drain opening points to the casing feet then tighten by the screws Press in the spacer and the cleaned or new anti friction bearing tighten by the shaft nut and secure by the safety tab washer Put on the bearing cover Screw on slightly the screws for fastening of the bearing cover and do not tighten Put the pump horizontally align the pump feet on a plane base and tighten crosswise the tie bolts The total play of the rotor is measured by alternating tightening of the bearing covers and until the rotor stop When doing the cover in direction of the movement has to be completely loosened before The degree displacement can be determined at the shaft end by means of a dial gauge The rotor adjustment to the middle of the measured play is also achieved by means of the bearing covers and by loosening the cover tightened at last and by re tightening the counter cover until the dial gauge indicates the correct value Then tighten the loosened cover evenly Put connecting pipe 1 with sealing on pump branches and tighten with screws studs and nuts Insert ruff key in the groove of shaft put on coupling half and the pump can now reinstalled into the system TESTWORK After assembly the following test work has to be carried out 1 Check the easy running of pump by rotating at the free shaft end In case the pump should be stuck probably the vane wheel impeller has been wrongly adjusted The trouble has to be eliminated Car
16. ty Incase the pump has not been in operation for a longer period of time it must be drained DISASSEMBLY Proceed according to the following order Switch off the power supply Disconnect the motor Drain the installation within the pump area i e between the slides at suction SYSTEMS VWS II TWO STAGE PUMPS and discharge side If necessary disconnect measuring probes and control instruments and dismount them Drain liquid out of the pump Dismountthe pump out of the installation If necessary flush the pump Hemove coupling half DISMANTLING OF THE VACUUM PUMP Please proceed as follows Hemove key Release hex bolt and remove outer bearing covers from drive side Remove the hex bolts from the bearing bracket With the help of bearing puller remove the bearing safely Unscrew the hex bolt of the stuffing box and remove Pull the mechanical seal out from the shaft Unscrew the nuts and remove the studs from the body Take off the casing cover Remove the casing of the first stage Open the lock nut of the rotor and pull out the rotor from the shaft Remove the key of rotor After removing the rotor take off the two control plates so the second stage casing can be remove Remove the second stage casing Remove the spacer between rotor and than second stage rotor Remove key of the rotor Hepeat the step 1 to remove bearing from the non drive side end ASSEMBLY Preparation for assembly Clean all p
17. ump parts carefully Observe that the sealing have no grooves and that the guide disc is plane Possibly the guide disc must be smoothed by means of abrasive cloth on a leveling plate Coat the running surface of guide disc except sealing fittings with Anabond 610 sealing gasket When mounting no foreign substances and no superfluous sealing mass must enter the pump ASSEMBLY OF THE PUMP Proceed as follows All marks must be in perfect alignment one or several parts are replaced which may effect the position of the rotor by their axial length the rotor must be PPISYSTEMS VWS II TWO STAGE PUMPS PPISTSTEMS VWS II TWO STAGE PUMPS 1 mounted again The has be machined such way that the length becomes about 0 20 mm greater than the width of the control plates when pressed together and the depth of the recess impeller Press control plates in the centering of the casing and tighten with screws Put on the shaft at the non driven side a the lock washer and screw on slightly the shaft nut Put key into groove of shaft Slip rotor on shaft Adjust a distance between the chamfer of the shaft and the front surface of the rotor Put the second key into the groove of shaft slip the rotor on to the shaft against control plates and spacer Put on slightly the lock washer and fasten it by the lock nuts The vanes of both rotor must be inclined to the sense of rotation Lay down the pre assembled casing
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