operation manual

EFFLUENT EVAPORATION PLANT

CLIENT

M/s. Birla Century

Division of Century Textiles & Industries Ltd.
Plot No. 826, GIDC Ind'l Estate
Jhagadia - 393 110
Bharuch Dist., Gujarat

ATTN

Mr. Sanjay Khujneri

OPERATION MANUAL: From: UNITOP AQUACARE
CAUSTIC RECOVERY PLANT THANE, INDIA
For M/s. Birla Century

Operation

PLANT OPERATION

HYDRAULIC TESTING
START UP
SHUT DOWN
EMERGENCY SHUT DOWN
START UP AFTER EMERGENCY SHUT DOWN

TIPS FOR SUPER PERFORMANCE

AIR REMOVAL FROM STEAM SPACES

CONDENSATE REMOVAL
MAINTENANCE OF LEVELS IN THE FLASH VESSELS
MAINTENANCE OF SYSTEM CONDITIONS

SAFETY PRECAUTIONS

TROUBLE SHOOTING
 PLANT OPERATION

HYDRAULIC TESTING

The basis of efficient working of evaporator is dependent on the

leakproofness of the system.
Air is a bad conductor of heat and hence there should not be any
scope for leakage of air once the system is in vacuum
Fill the feed tank with water.
Start the feed pump. The water starts filling the system through the
preheaters and then to the heater.
Open the top threaded nipple to allow the trapped air to the atmosphere.
Keep open all the valves ( except the ones open to atmosphere directly ) in
order to allow it to reach all the parts of the system

Allow the water to fill in till the water comes out of the vacuum pump outlet.
Close the vacuum discharge valve and continue pumping till pressure
reaches 2 -3 kg/cm2.
Observe if any leakage is taking place through welded or flanged joints.

Tighten the flanges from where leakages are observed.

Mark the places of weld leakage. After draining the water from that section
repair the welding and test again.
Leave the system in pressure for about 2 hours. If no drop in pressure is
observed then the system is OK.

Also take the vacuum test by holding the vacuum after stopping the vacuum
pump for about 2 hours. The method of taking vacuum is as instructed in pt 3
( Evacuation of the plant )
If no drop in vacuum is observed then the plant can be safely started.
START-UP

1 PREPARATORY:

Check for availability of the following:

Sufficient feed for running 1 shift
Cold and filtered water supply for pump gland cooling or mechanical
seal cooling of Gland
Cold water supply for water ring in vacuum pump
Steam pressure before the PRV of 7 kg/cm2

Check Feed Quality:

Feed quality should be monitored in lab to check presence scaling salts.
( Check the TDS/ GPL of effluent and PH of effluent before start of the plant and note
down the readings after every hour. )
Antiscalant is ideal in the feed to prevent scaling of Exchanger Tubes
Make sure that antiscalent and defoamer dosing arrangement has made at feed pump suction
and also enough quality of antiscalent and defoamer with desired concentration.

Make sure that the following valves are closed while other are open:

- Drain of Heat Exchangers E9, E11,E13,E15

- Conc. Liquor sample E20
- Vacuum bleed V5
- Cond Sample valve D12
- Suction and Discharge of PumpsE3,E6
- Steam trap sample valves D2,D5
- CIP Valves to Heaters C5,C6,C7,C8
STEAM inlet valve should be closed fully while taking vacuum.

Make sure that:

Gauges are in proper working condition. This will help in verifying
process parameters during troubleshooting.

All other valves are open:

Vent valves V1,V2,V3,V4
Steam bypass valves D1,D4,D6.D7

Keep following valves crack open upto 5 - 10%

- Feed to Vessels E8,E10,E12,E14
Keep open air inlet valve so that all pnumatic on/off valve will get open during vacuum.

2 ENERGISE PANEL BOARD:

Start condensate pump to remove all the condensate in the system

resulting from previous operations from the Last Condensate Flash Tank.
Close the valves at suction and delivery line of all pumps
After condensate removal put condensate pump in automation mode.
3 START PLANT EVACUATION:

Start the blower of the Cooling Tower and then the recirculation pump so as
to start condensing any balance vapor from the system.
The flow is adjusted so as to reduce the chances of water drops through blower
as well as to form maximum condensing.
Start Vacuum Pump
Open valve for water to Vacuum Pump.
Regulate water supply and measure actual water flow till it is at desired value.
Wait till the system reaches up to 26" - 27" Hg vacuum.
This will take up to 30 - 40 minutes.
If not, check if:
Any valves open to atmosphere are in OPEN position.
Water flow is irregular or not matching with specified rate.
Any air leakages from plant welded / flanged joints.
If necessary [ in case of excessive time ], take Hydrotest of the plant at 4 bar to
locate & rectify the leaking points.

4 START STEAM:

Check if Boiler has attained 7 kg/cm2g steam pressure.

Drain off the condensate from steam header at plant

NOTE= Make PRV setting as per desired pressure requirement at the downstream of PRS of the plant.

Open the steam valve in slow and steady fashion so that:

Pressure / Vacuum in both effects is at desired level.
Recirculation in the effects is adequate

Start the feed pump immediately after starting the steam . Liquor starts entering
the flash vessel through the tangential entry in a vigorous fashion.

Observe that :
- Due to live steam introduction in Effect 1 the liquor in the Effect will get
heated & evaporation starts.
- Due to Evaporation Thermo siphoning effect takes place in the effect and
the liquid enters effect 2.
- Vapor & Liquor mixture comes in the Flash Vessel through cyclonic
entry. The vapor is stripped off any liquor droplets and enters next
Heater, Preheater and Water Heater, if any through suitable circuitry.

- With sufficient evaporation in Effect I, the liquor circulation starts in

Effect II and so on.

- The rate of liquor circulation as seen through the sight glass of the
Flash Vessel is a direct indication of rate of evaporation in that effect.

The reason for inadequate rate of liquor circulation could be:

- The liquor has not reached its boiling point under the prevailing pressure.
- Steam supply pressure is not adequate.
- Improper venting for non-condensables.
- Improper withdrawal of condensate.
 Adjust the valves of liquor inlet to all the effects such that the inflow
would match the requirement as to maintain the level to tangential level.
Adjust the delivery valves till an equilibrium is attained and then valves
need not be touched.

Due to increased evaporation in the Effect I, vacuum in subsequent

effects starts dropping. Adjust the Vent Valves in each effect so that
only non-condensables and not vapors escape to vacuum system.
Also bypass of Steam Traps may be adjusted so that condensate is
not accumulated due to inadequate pressure differential and at the
same time no vapors are allowed to pass through condensate line.

The live steam and cold water should be steadily / stepwise

increased in such a way that:

- Pressure / Vacuum in all the effects is at desired level.

- Recirculation in the effects is adequate
- Wash liquor preheating is adequate (at temp 5 to 10 C or less than the
vapor temperature in Effect I)

A TYPICAL CIRCUIT FOR RISING & FALLING EVAPORATOR:

In Rising & Falling type of design, Feed to any effect enters Rising side of Heater
say H1, and thro' falling side of H1, it enters FV1 and concentrated liquor is
transferred to the next lower stage.

The Heaters are 1 - 2 pass type with bottom bonnet having partition plate.
PLEASE ENSURE ALWAYS that the gasket partition plate is firmly in place
by looking / feeling from sight glass provided in one of the passes.

5 CONDENSATE HANDLING: Procedure for starting pump

under vacuum:
Condensate from H1 starts falling in
CFT1 by gravity. - Open Priming line valve
When Evaporation has gathered - Open Suction valve
momentum, it is time to close the steam trap - Ensure dripping water to the gland of the
bypass valves. pump
Check if condensate is falling even after - Start pump
closing the bypass valves. If not keep them - Ensure pump discharge by opening
open till check is successful. sample valve
- Close sample valve, Priming line valve
Keep closing the condensate bypass - Open delivery valve
valves progressively one by one as - Open the delivery valve in such a way
soon as boiling is observed in (and monitor the same during Start-up)
successive effects. This takes about that the flow is continuous at desired rate
10-15 mins from the time the steam is started.
Please refer the figures at the end of this
As soon as as condensate is observed in section
CFT 2, start Condensate Pump Adjust
delivery valve of condensate pump in such a manner that the flow is continuous.
 The adjustment of the following valves will have to be done till the
concentrations in each effect reaches the desired level:
- Conc. liquor outlet
- Steam
- Condensate pump discharge

6 PRODUCT REMOVAL

As soon as the liquor enters the third vessel start the product pump.
Open the sample valve of the product pump and continuously
pump it to the feed tank at a very low speed.
As soon as concentration of the effluent reaches the set value, the
control valve opens and the effluent flows to the Pusher Centrifuge unit.

Adjust delivery valve to control the flow at desired rate and

monitor liquor concentration continuously. Adjust delivery valve
accordingly.

The Plant is supposed to reach

its steady state conditions when
the parameters such as
concentration, level, temperature
& pressure in each Effect
remains unchanged with
reference to time. The Plant
will remain working at these
conditions continuously even
without supervision.
Maintenance of Parameters:
A periodic observation of the parameters
is required because the wash liquor
concentration changes from time to time
and to that extent periodic monitoring and
adjustment is required.

8 DESCALING / ACID CLEANING

As such the frequency of descaling is only determined by the amount of scaling

impurities present in the wash liquor there are certain thumb rules based on experience
for the cleaning frequency.
Frequency
Knit Fabric Grey 60 - 75 days
Knit Fabric Bleach 90 - 120 days
Woven Fabric Grey 15 - 25 days
Woven Fabric Bleach 90 - 120 days
Denim Fabric 60 - 75 days
Effluent Evaporator 1 - 7 days

Prepare a 5% concentrated solution of Nitric Acid in a CIP Tank. The quantity of Acid is as
per the size of the plant and is mentioned in the Execution documents.

Fit the suction of the CIP pump to the CIP Tank and the outlet to Nozzle through a
flexible hose pipe.
The acid enters back in the CIP Tank through Nozzle
Recirculate the acid through the heater tubes for about 2 hours
After the scales are removed they also have to be cleared from the bottom bonnet
Open nozzle and sight glass of the bonnet and remove the scales manually

Clean each heater in similar fashion and then drain all the acid from the heater
The plant is ready for operation
There are 2 Pumps which extract Liquid under vacuum. Energise Solenoid valve on Priming line
Their start up is to be automatic in following sequence: Wait for 2 secs
Start Pump
Wait for 2 secs
Denergise Solenoid valve on Priming line
Energise Solenoid valve on Discharge Line.

1. System Not Operative 2. Open Suction Valve ( V1 )

& Priming Valve ( V2 )
Liquid fills up pump &
priming line upto liquid level

3. Start Pump 4. Close Priming Valve ( V2 )

Open Sample Valve ( V3 )
Liquid gets pumped to the
vessel under vacuum

If it does not, reasons could be:

- Leakage at Suction Flange /
Pump Gland / Pump Gasket
- Restrictions / Choking at
pump suction
- Liquid head in Receiver is
not high enough to prevent cavitation

5. Close Sample Valve ( V3 ) Check Quality of Sample

Close Discharge Valve ( V4 ) If it matches with desired quality, proceed next.
Figure 1: Operating sequence: Pumping of liquid From Receiver under vacuum
SHUT-DOWN
1. Start reducing live steam valve steadily in such a way that there is no
sudden drop in the pressure of the Effect (which may give rise to foaming
or to Effluent losses through condensate).

Heat Recovery from the plant

During Shut-down:

When there is enough time, the Plant shut- down should be planned in such a
way that all the heat stored in the system is properly utilised.

However, during shut-down, a great care should be taken to control the foaming in
the effects to avoid effluent losses with the condensate.

2 Stop feed pump and close discharge valve of feed pump.

3 Stop axial flow pump one by one as per liquid level.

4 Stop procuct pump as soon as fourth flash vessel level will get down.

5 Stop pusher centrifuge after 3-5 mins of closing of product pump.

6 Stop Vacuum Pump and release vacuum slowly.

NOTE : Always keep condensate pump in automation mode so balance condensate will get
removed automatically.

Ensure that the valve positions are as described in instruction (1) of

"START-UP"
Open the vacuum bleed valve to break the vacuum.

Switch off the Panel and close water supply valve to Vacuum Pump and
Process pumps.

EMERGENCY SHUT-DOWN
Open the vacuum bleed valve Emergency plant shut-down
to break the vacuum. becomes imperative due to:

Stop the steam. o Power failure

Ensure that all the pumps are
stopped.
Close valve of fresh water mains.
Ensure that the valve
position are as described in (1)
of "START-UP".
o Failure of critical equipments like
steam trap, pumps.
o Steam hammering in and around
system
o Vapour locking/air locking at pump
suction.
o Failure of condensate or concentrated
liquor pump to suck the fluid under
vacuum and pump the same.

Close the liquor transfer valves between the effects.

START-UP AFTER EMERGENCY SHUT DOWN
Follow instruction (1)/(2) of "START-UP" Avoid foaming during Start-up:

Start Vacuum / Water Pump.
Start opening vacuum bleed
valve / cooling water valve, so
that vacuum application on the
system is only gradual.
Continue till the final vacuum is
reached in all the effects.
During the process of vacuum
application, vapours are generated
and condensed. Hence,
- Open the bypass valves of all
steam trap assemblies.
- Run the condensate pump
- Then open the valve in the
condensate delivery line.
When the final vacuum is
reached, start the live steam and increase the rate steadily.
The plant, which is shut down due to
emergency, has to be started subsequently
with a great care. The liquor in the plant,
especially in the first effect has temperature
higher than the saturation temperature of the
final vacuum.
Any excessive application of vacuum will
result in the increase in level and foaming in
flash vessels, especially of the first effect.
Direct application of the full vacuum will
cause excessive foaming accompained by
heavy losses of effluent in condensates. If
full vacuum is avoided, non-condensables in
the systems are not adequately removed,
thereby impairing considerably the heat
transfer rate and plant capacity for quite
some of time.

Start wash liquor and concentrated liquor pumps.

9 MAINTAINING LOG BOOK:

Keep observing the readings on hourly basis for each stage & maintain the log book:
Pressure / vacuum, bar / mm Hg Vac
Temperature, C Maintenance of Parameters:
Concentration of liquor as Sp Gr / %
Condensate rate, LPH A periodic observation of the parameters
Condensate TDS, ppm is required because the weak liquor
concentration changes from time to time
If there is any variation in readings, take and because Exchanger Tube Fouling takes
necessary action by either adjusting the place on continuous basis. Hence, periodic
vent /condensate bypass valves or the monitoring, record & adjustment is required.
levels in FV / CFT. This will help diagnoising problem with any effect and whether
descaling or any corrective action need be taken.
 TIPS FOR SUPER PERFORMANCE

Effluent Evaporation Plant, which is Multiple Effect Evaporation Plant, is tailor-designed

to suit customer's needs. Hence, rather than putting down step-by-step
troubleshooting operation procedures, it is felt proper to highlight the basic principles
governing the plant operation and giving generalised guidelines for efficient plant operation

AIR REMOVAL FROM STEAM SPACES

The non-condensables even in small percentage can drastically cut down the rate of
steam condensation and also increase the corrosion problems. While co-efficient of
condensation of steam at a temperature difference of about 10 C is about 10,000
Kcal/Kgm2C, it reduces to 5,500 Kcal/Kgm2C with 1% air by volume in it and to 4,000
Kcal/Kgm2C with 2% air in it.

The rate of condensation drastically falls Non-Condensables - Real Villain:

down in the presence of
Non-condensables due to two reasons. Presence of Non-condensables
increase resistance to Heat Transfer
1. Thermal conductivity of air is lowering UD and decrease the driving
very poor, just 0.06% that of steel. force for Heat Transfer (LMTD)
Net Result : Plant capacity is reduced
With this even a small film of air drastically.
around the heat transfer surface can create unproportionately large resistance to
heat transfer.

2. In presence of air, the temprature of steam falls down in accordance to Dalton's law
This means a lesser temperature difference - lesser driving force for heat transfer
Ensure removal of
Care should be taken to remove the Non-condensables from :
non-condensables to maximum extent
before the plant is started. o Empty space of exchanger before plant
start-up
Non-condensables are removed o Air from the steam mains, before plant
manually through valves to vacuum line start-up
or by automatic air vents. The vacuum o Air, Oxygen and Carbon-dioxide dissolved
system of the plant should be sized in the feed liquor & in cooling water in direct
for continuous removal of contact condensers.
air/non-condensables at the desired o Air leakage through the joints of the plant,
vacuum level. when under vacuum
The vacuum system should create operating vacuum in reasonable time (20-40 mins.).
Any deviation from this would indicate that some disorder has developed in the
vacuum equipment or that the plant leakages have increased beyond a limit

If the vacuum equipment has been found in order, complete plant should be tested
hydraulically for a pressure of 2-3 Kg/sq.cm (g).

CONDENSATE REMOVAL:

Condensates from all the effects have to be removed regularly, failing which
the heat exchanging surface will be flooded with condensate, leaving lesser or
no surface for steam condensation. This will result in increase in pressure in
the preceeding effects and decrease in the pressure in following effects. This
would give rise, in turn, to heavy entrainment loss in following effects. When the
accumulated condensate is somehow subsequently discharged, the pressure in
the preceeding effect will drop down from the temporarily increased level to
normal level. This, too, would give rise to entrainment loss through the
preceeding effects.

Check irregular condensate discharge for the following:

o Inadequte pressure differential across the trap.

o Malfunctioning of SLR (Steam Lock Release) TV (Thermostatic Vent)

attachments or condensate release arrangements of trap.

o Choking of strainer/ trap

o Improper venting of exchanger surfaces.

o Air leakage before trap, or through Condensate or Product Pump glands

when under vacuum.

During Start-up of the plant, the condensation is very fast, giving heavy load
and steam pressure is quite low resulting in inadequate pressure differential across
the Steam Trap to discharge the condensate. In such case, by-pass valve across
steam trap should be slightly opened, till the Steam Chamber develops adequate
pressure.
MAINTENANCE OF LEVELS IN THE FLASH VESSELS

It is necessary to maintain the levels of liquor in the Flash Vessels to a desired

height.

In forced circulation type evaporation system, higher level would elevate the
boiling point of liquor inside the heat exchanger due to hydrostatic head and
would ensure that no evaporation takes place in the heat exchanger

In natural circulation thermosyphon type evaporators, lower level would

diminish the recirculation rate, while the level above the recirculation entry
also would reduce the recirculation rate, due to higher back pressure

The evaporation rate decreases along with the recirculation rate. Hence, i
is necessary to maintain the levels at correct point.

Too high levels would obviously increase the entrainment losses of the
liquor and would even cause syphoning of the foam or even liquor when there
is accidential and sudden decrease in the pressure of the system

Sudden variation in levels also results in changes in pressure / temperature

conditions of the plant which finally results in reduction in plant capacity and
also in increased losses with condensate.

MAINTENANCE OF SYSTEM CONDITIONS

Maximum steam economy can be

achieved by maintaining system
conditions at recommended level.
Any variation in these condition is
to be executed gradually, in case
the feed liquor condition is different
than the specified ones.
Ensure stable system conditions:
o Concentration of liquor
o Temperature of liquor
o Pressure of vapours
o Steam pressure
o System vacuum

Sudden reduction in the pressure of any of the effects will invariably result in heavy
entrainment loss of liquor through the condensate or even syphoning of the foam o
liquor through the condensate in extreme case. Any abrupt action of the following kind
is likely to result in sudden reduction of pressure in one/all of the effect

o Reducing live steam pressure.

o Increasing liquor flow to one of the effects for manipulating concentrations
o Venting heat exchangers.
o Application of vacuum to the idle but hot system.
o Sudden accumulation or removal of condensate from any of the effects
 SAFETY PRECAUTIONS

Apart from efficient operation of the plant, the operator is also responsible for
its safe operation, so that no damage is caused to the personnel or property

The damage to the property can be

minimised by operating the plant as Safety to life & property FIRST
per the standard procedures set for
start up, shutdown and maintenance. Various norms specified for preventive
maintenance should be strictly adhered to.

Personnel safety can be ensured by using the safety equipment like

Goggles: for the protection of eyes.

Face shields: for the protection of the full face.

Gloves: for the protection of hands.

Gumboots: for the protection of legs.

Apron: for the protection of the body.

It is true that the use of these safety

equipments impose certain restrictions Accidents affect you, your friends & families.
on the body movements and hence
are normally disliked by the operators.
However, in case of an accident, should it ever occur, its effects are long lasting and
would be affecting not only the person concerned, but his friends and families as wel

Hence, it is considered imperative to use the safety equipments as and when

found necessary. In case of any defective safety equipments, the defects
should be reported immediately and rectified.

In case of any spills or splashes of Effluent solution on the body or

eyes, the same should be washed off immediately under the safety
shower or eye-wash fountain. The clothes soaked in the solution
should be removed from the body immediately. Subsequently the matter
should be referred immediately to the dispensary.

Fire fighting equipments in the plant

should be in working order & the plant Safety shower & eyewash fountain are MUST.
personnel is trained to use them
 TROUBLE SHOOTING:
EVAPORATION PLANT

The Trouble shooting of Evaporation Plant has to be done on emergency basis when the plant faces one of the two
major problems:

o Plant fails to give Rated Capacity, reflected in one of the following Operating Parameters:
Lower Product Concentration
Lower Product Flow Rate
Lower Condensate Flow Rate

o Plant fails to give Rated Solids Recovery Efficiency, reflected in one of the following Operating Parameters:
Lower Product Concentration
Lower Product Flow Rate
Higher pH / TDS of Condensate

We wish to undertake here a detailed Study / Analysis of Conditions under which such aberrations in operation occurr.

NOT ENOUGH PLANT CAPACITY

SOURCE OF TROUBLE SOLUTIONS

1 Feed Concn

Lower Feed Concn affects Product Concn adversely, A plant designed for a certain ratio will
& vice versa. always behave in same fashion
For example, Adjust the conc of feed to rated level.
A plant designed to evaporate from 3% feed to 30%
concentration, if fed feed at 2% concentration will concentrate
it to a maximum of 20%

2 Steam Pressure

Evaporation Plant Capacity depends on the Total Temp Diff
available and hence will be lower with lower Live Steam
Pressure available.
For example,
If a plant designed to operate at 3 bar pressure is supplied 2
bar pressure, there will be a drop in capacity by around 15%
Adjust the steam pressure to rated level.
Check for Abnormally high draw-off of steam in
the places near tapping to plant and correct
such situation.

3 Last Effect Vacuum

Lower vacuum results in higher boiling point at the last stage

and hence reduces the total temperature difference - Driving
Force available. If the lower vacuum is due to insufficient
removal of air it also adds to poor heat transfer. Both the
reasons together, reduces Plant Capacity.
Hence, we discuss here reasons for vacuum nor being
maintained, point by point.
(a) Leaky Joints

The vacuum system should create operating vacuum in Check for any leakage by soap water
reasonable time of 30 mins or so. Deviation indicates: method or by hydraulic test. Tighten all
Disorder in the vacuum equipment. leakage points.
Plant leakages beyond normal limit.

If the vacuum equipment is OK, Plant should be hydro tested

@2-3 Bar(g). to locate the leaks, which should be promptly
corrected.

(b) Valves are open inadvertently.

Any of the valves when open to atmosphere, allow the outside Close all valves open to atmosphere
air to gush in and reduce / destroy the vacuum.

(c) Vacuum Pump does not develop sufficient vacuum

- Back Pressure

Discharge line of pump not fully open to atmosphere through Correct the situation
exhaust silencer

- Vacuum Pump water inadequate

Provide adequate water to Vacuum Pump to achieve its best
performance. Even higher water flow also reduces the
evacuation capacity greatly because vacuum pump wastes its
energy input in pumping water rather than pumping off air. Also
excessive water pressure can damage vacuum pump
mechanically severely and also overloads the motor.
Adjust the water requirement to desired
level as mentioned in manual.
As a thumb rule,
Water required in LPM = 2 x Motor HP
If necessary, Use a pressure reducing
valve to limit the pressure to 12 psig

- Vacuum pump Cavitation

Remove suction pipe off the suction flange. Close the 2 brass Call the manufacturers service engineer
cocks. If loud rattling sound is heard, due to cavitation from
pump, it is working in order.

- Automatic drain Valve operation

Check by placing a finger over the automatic drain valve If leakage is indicated, remove rubber
opening for leakage of air. ball, clean and remove any foreign
Check if any excessive leakage of water from side covers particle if present and refit or replace.
Check if gland packings are worn out, if so, replace.
 - Wear & Tear of parts of Vacuum Pump

Dismantle the pump to check

Rubber balls in control disc Replace, if required
Side cover packing thickness Replace, if required
Control disc and side face of impellor wearing Replace, if required
Shaft protection sleeves wearing Replace, if required
Foreign matter or scales on Impellor Replace, if required
Gland packing Replace, if required
Alignment and distance between coupling halves Correct

4 Condenser Cooling Not Adequate

(a) When with Water Heating, Cooling Water flow is inadequate

Adequate supply of cooling Water to condenser is necessary Correct as per rated condition
to fully condense the water vapors from the last effect. Remove air lock, if any, in Water Supply /
Discharge Piping.
If not, any size of Vacuum Equipment would fall short.

(b) When with Water Heating, Cooling Water temp. is high

When the cooling water is supplied at temp higher than the Correct as per rated condition
designed one, the driving force for the condensation is not
adequate. This results in incomplete condensation of vapors
and fall in Vacuum.

(c) When with Adiabatic evaporator, its operation not Efficient

- Evaporative Fills melting

In case of ineffective cooling the adiabatic fills may melt due Replace the fills
to contact with high temp feed and result in insufficient cooling

- Evaporative Fills getting displaced

For some reason, Evaporative Fills get displaced from its Rearrange the fills so that bypassing of liquor /
position, leaving uneven flow of air through cross section of air is avoided
adiabatic Evaporator, resulting in uneven operation of
Adiabatic Evaporator.

- Recirculation pump not pumping properly

Any obstruction in free flow due to any of the reasons may

result in insufficient flow and hence lesser condensation in
condensors
Foot valve of pump not working Replace or repair
Foreign material in the casing of pump Remove the material
Leakage in suction of pump Tighten all fittings upto suction of pump
Incorrect sizing of pipeline Contact manufacturer
 - Blower not functioning

Hot air has to be sucked out in enough capacity from the

Adiabatic Evaporator. If not, then back presure is generated
and liquid does not get cooled effectively
Impeller worn out Replace 'Impeller
Motor not running effectively Check motor by megar test for current, RPM
Rewind / replace if necessary.

- Spraying system not working

Clogging in spraying system may result in reduced flow, Clear muck, foreign particles from system.
resulting in hence insufficient cooling

- Incoming feed too hot

If incoming feed is at higher temperature than designed then Correct the Temp as per rated condition
outlet of Adiabatic Evaporator is at higher temp and hence
may result in lower vacuum

4 Condensate Discharging Inadequate - causing Condensate Built-up

Inadequate pumping leads to condensate logging in shell of
Condensate Flash Tank-CFT resulting in higher level of
Condensate in Exchangers, resulting in:
Lower area for heat transfer
Knocking in heaters
In extreme case, water enters back into flash vessel through
vent line from top and dilutes the very liquid which is being
concentrated
If condensate is not drained effectively by
Steam Traps / Control Valves, open the
Bypass Valves to control the situation.
When Boiling liquid is to be pumped
under vacuum, care has to be taken to
prime while starting pumping. Prime the
pump as per procedure given in the
Operation Manual.

(a) Leaks before pump

When Traps / Pumps are working under vacuum, any leaks Tighten all the flanges, valves, fittings which
before them thru' screwed / flanged joints, mechanical seal are before the pump and CFT
causes an influx of air, preventing flow of condensate. This
will make condensate drain rate erratic.
 (b) Improper System Pressure

For proper Evaporation rates, System Pressure should be

properly balanced & should be closer to the specified ones.
The deviation can happen due to:

F Inadequate venting of Exchanger Adjust vent valve to requirement.

Results in non condensable air presence in system
reducing the heat transfer

F Unduly open Vent Valves of effect Adjust vent valve to requirement.

Results in steam being passed to subsequent effect
along with air reducing the temperature difference
between stages This problem is indicated by
excessive vapor / steam coming from vacuum pump.

F Unduly open Bypass Valves of Traps Ideally bypass valves of trap should be
Results in steam being passed to subsequent effect fully closed. If not then observe if level of
along with condensate reducing the temperature condensate is always above pipe at centre
difference between stages of sight glass. If so, then it is OK

F Condensate logging of Exchangers Open immediately bypass valves of trap /

Results in reduced area for evaporation pump to take care of the problems on
emergency basis & restore the same later.

5 Evaporator Levels

Too high levels or sudden variation in levels If possible, allow liquid to flow to next effect
Increase the risk of entrainment losses of the liquor. through bypass valve and then through
Cause varying back-pressure on Steam pressure, product pump. Also adjust flow according
thereby showing fluctuating Steam pressure. to the evaporation / condensate rate

6 Venting Status

The non-condensables even in small percentage drastically
cuts down the rate of steam condensation, reduce the plant
capacity and also increase the corrosion problems.
Care should be taken to remove non-condensables to
maximum before plant is started, manually through vent valves
to vacuum system and then as & when required.
Vent valves should be kept open only
around 15-20% only to allow non
condensable air to pass through without
steam being passed along

7 Leaky mechanical seal of Product / Condensate Pump

Leaky mechanical seal of Product Pump would allow gland Open the pump seal and replace the worn
cooling water to enter evaporator thereby diluting conc product. out surface

Leaky mechanical seal of Condensate Pump would allow air

to enter the casing of pump and result in inadequate pumping
of condensate.
8 Improper heat transfer to Liquor in Evaporator

This is very serious problem and gives indication of several

internal aberrations, like:

(a) Scaling of exchanger tubes

Presence of calcium, Magnesium salts and silica are the Descale the tubes manually or by acid as per
major cause of all scalings though they cannot be entirely the procedure given in the operation manual
avoided we can segregate the effluent to give minimum of
such salts. The major source of these salts are soft water
regeneration rejects, cooling tower and boiler blowdown. If
these effluents are avoided in ETP and used elsewhere such
as in Solar ponds or for fly ash control then major source of
scales is avoided.

(b) Cut in Gasket of Heater Bonnet

If the gasket provided on the bottom bonnet gets broken then Replace the gasket as per procedure
then liquid will short circuit the tubes and enter into the flash shown in operation manual.
vessel without getting heated. This can be noticed by higher
pressure in shell of heater but low temperature of liquid in
Flash Vessel. , the liquid level in lash vessel rises very fast at
the same time no liquid is transferred to the next effect.
OPERATION MANUAL: From: UNITOP AQUACARE
CAUSTIC RECOVERY PLANT THANE, INDIA
For M/s. Birla Century

Maintenance

FABRICATED EQUIPMENTS
HANDLING & ERECTION
HYDROTEST
PAINTING
THERMAL INSULATION:

INDUCTION MOTORS
HANDLING & STORAGE
INSTALLATION
ELECTRICAL CONNECTIONS
MAINTENANCE

CENTRIFUGAL PUMPS
INSTALLATION
PUMP PRIMING
PUMP STARTING
PUMP STOPPING
PUMP RESTARTING
LONG SHUT DOWN
MAINTENANCE

WATER-RING VACUUM PUMP

OPERATION
FACTORS AFFECTING PERFORMANCE
TROUBLE SHOOTING

TOP MOUNTED LEVEL SWITCH

MOUNTING AND WIRING GUIDANCE
RESETTING OF DIFFERENTIAL

SCHEDULE OF PREVENTIVE MAINTENANCE

 PLANT EQUIPMENTS
INSTALLATION, OPERATION
& MAINTENANCE

FABRICATED EQUIPMENTS

Multi-effect Evaporation Plant consists of fabricated equipments out of carbon / stainless steel
such as filters, flash vessels and various exchangers.

HANDLING & ERECTION

CHECK which of the equipments are Stress Relieved, to improve Corrosion resistance.
Since Effluent has a peculiar stress corrosion for carbon steel at higher concentration
and temperature, the equipments are Stress Relieved.

Hence, extra care should be taken in installing these equipments so that no stresses are
induced during erection due to misalignments or misfits. Hence, following care must be
taken during erection:

& Welding should not be permitted on the equipments for any purpose such as:
- Lifting hook
- Temporary / permanent supports for piping/cables/lights
- Insulation Spikes

& All the equipments should be firmly supported / bolted on the structure in levelled
condition before any piping connection is started.

& All piping should be fabricated and fitted in such a way that it is perfectly aligned
and no undue stresses are induced in piping or equipments.

Sight glasses / Level gages form the weakest Take Care of Sight Glasses/
part of the plant. As it is, when properly Level Gages:
assembled, these components could stand the
hydrotest very well. But any un-even pressure Sight glass/Level gages are the weakest
in tightening make them extremely parts of the system under pressure.
vulnerable. Hence, an experienced person Take care of them.
should do this job under proper supervision.

Heavy Fluctuations in level / foaming during operation, makes the glass wet and dries off
the Liquor Film later. Repetitions of this cycle leaves a thick layer of dried Film on glass.

When concentrating Effluent, Solid layer at high temperature attacks glass and
causes pitting. Hence, Sight glass should be cleaned as soon as layers are
observed on it. The pitted glass when tightened during hydrotest develops excessive
stress and may break off once the system attains temperature during working. This can
cause serious accidents inflicting injuries to people around.
HYDROTEST

All the equipments have been hydraulically tested for adequate pressure before
despatching from the factory. Hence, no hydrotesting need be done during
installation. However, after all piping connections have been made, the
complete system should be put under hydraulic pressure to test the tightness of
the flanged/screwed joints of the plant.

The simplest method of testing the plant would be to pump the water through
the feed pump while all the valves of the plant except discharge of Conc. Liquor
pump and equipment drain valves are in full open position. The water will fill up
all the plant and finally would get out of vacuum pump. When valve at vacuum
pump is closed, the system would develop pressure and the leakages can be
detected and rectified. If there are any major leakages, the water pumping has to
be stopped, water drained, defects are rectified and the procedure is repeated.

Special care must be taken to see that Blinds have gaskets on both the sides
and all gaskets are cut correctly [ see Fig ]

CORRECT WRON G

SHAPE OF RING GASKET

WRONG POSITIONING O F RING GASKET

FLANGE OD-3mm

FLANGE ID+3mm

ABSOLUTELY SAFE FULL GASKET

VACUUM TEST

As a fool-proof method, it is worthwhile to carry out Vacuum Test as follows:

Start Vacuum Pump

Open valve for water to Vacuum Pump.
Regulate water supply and measure actual water flow till it is at desired value.
Wait till the system reaches up to 26" - 27" Hg vacuum.
This will take up to 30 - 40 minutes.
If not, check if:
Any valves open to atmosphere are in OPEN position.
Water flow is irregular or not matching with specified rate.
Any air leakages from plant welded / flanged joints.

After final vacuum is achieved, stop vacuum pump & leave the system as it is.
The plant should be able to retain 90% of vacuum during 3 hours.

PAINTING:

All the structure equipments are painted with one coat of zinc Chromate Red
Oxide Primer, followed by two coats of Chlorinated Rubber Paint to protect the
equipments from atmospheric corrosion before they are installed.

All structure and other exposed parts are to be given one coat of Chlorinated
Rubber Paint. No painting of equipment is expected as all the equipments will be
covered by Thermal Insulation.

THERMAL INSULATION:

To avoid heat losses through exposed surfaces of equipments, the thermal

insulation of Typical Specifications as follows is recommended:

Light Resin Bonded Glass Wool Matress

Thickness: 50 mm
Density: 100 Kg/m3
Operation Temp: 100 - 150 C
With one side wire netting of 3/4" x 24 SWG with PBH packing.
Sheet Metal Cladding: 24 SWG GI sheets for piping
22 SWG GI sheets for vessels
INDUCTION MOTORS

HANDLING & STORAGE

Make sure that right type of motor as ordered by you has arrived and
it is not damaged in transit. In case of any such problem report
immediately to our office.

Store the motor in a clean dry place if it is not to be installed immediately.

INSTALLATION

See that the motor rotates freely by turning the shaft by hand.

Replace the grease charge of bearings if the motor has been stored
for longer than 18 months.

Check the insulation resistance by applying a D.C. voltage of 500 V.

if it is show low due to moisture dry out the stator winding till the
insulation resistance increases above one megaohm by any of
the accepted methods ( Ref : IS900 - 1992 )

Remove anticorrosion coating on the shaft with petrol, white spirit

or kerosene. Do not scrap the coating.

See that the machined surface of motor feet (or flange face ) and
also the surface on which the motor is mounted is clear and perfectly
in level.

The coupling part to be fitted on the motor shaft are to be properly

balanced. The bore and key way are to be machined accurately.

The recommended tolerance for the bore diameter is H7.

The coupling parts or pulley must be carefully fitted by means of

special tackle for which a tapped hole is provided at shaft end. Blow
must be avoidedsince they might damage bearings. The tackle can
also be used for removal of coupling.

ELECTRICAL CONNECTIONS

Use appropriate size of cables for connecting the motor.

The supply voltage should be same as given in the rating plate.

Unless otherwise specified the tolerance is 10% of the rated voltage.

Connect the motor in accordance with the connection ( Star or Delta )

given in the rating plate and connection diagram given inside the
Terminal box cover.
 Connect earth terminal effectively for proper protection.

Normally 3 phase motors upto 2HP have their windings connected in star
( Y). These motor have three terminals and are meant for direct on line
starting only.

Motors above 2HP/have windings suitable for delta ( D ) connection.

These motors can be started with a Y - D starter or direct on Line
starter using connecting links as shown in the connection diagram.

While connecting the cables to motor terminals please ensure that the
cable in properly secured and clamped and it does not exert any tension
on terminals.

It is recommended to use starter with single phasing preventor over

load relay etc. for 3 phase motor.

MAINTENANCE

The bearing are prelubricated and maintenance free. Operating conditions

premitting, bearings should be cleaned at intervals of about 10000 operating
hours, with trichloroethylene or clean petrol.
While lubricating please see that the bearing are well lubricated and about
one third of the space within bearing covers is filled with grease. Over filling of
grease is not recommended. While regreasing motors with regreasable
bearing, keep the grease outlet open and fill grease when the motor is
running so that old grease/excess grease will flow out.

Balmer Lawrie LL3 and Shell - MP 3 are recommended for use in motors. Mixing
of different greases should be avoided.

When motor is opened protect bearings from foreign particles and dirt by
wrapping them with clean paper or polythene sheet.
During reassembly of motor ensure that wavy washer and brass washers are kept
in their position and bearing covers and secured properly.
Clean the entire path of the cooling air on the motor at regular intervals.

The temperature of the motor, judged by hand feeling, could be misleading. In the
case of suspected overheating the actual temperature should be measured with
thermometer and should be compared with the premissible temperature rise
according to the temperature class of the motor.

Overheating of the motor may be due to over loading of motor, too low or too high
supply voltage, frequency fluctuations, over greasing of bearing, foreign material
in the air gap between stator and rotor. Necessary suitable corrective action is to be taken

When ordering spare parts state the motor type, machine number, type of
construction as shown in the rating place, part description given in the part list
and number of units required.
Special additional installation instructions of IP55/IP56 construction motor.

Conduit entries are fitted with threaded plug and are sealed. Open the plug and
clean threads before fitting cable gland. Use double compression glad and seal
the threads of glands with sealing cement. This will ensure IP55/IP56 Protection
of the cable entry.

After the cable connection fix the T. Box properly. Ensure that the rubber gasket
provided is not dislocated or distorted and fixing screws are fully tightened.

Whenever possible it is recommended to cover the motor from direct heating by

the sun. Provide a canopy over the motor.

Additional maintenance instructions of IP55/IP56 motor.

The motor shaft is provided with oil seals / 'V' rings on both ends. Drain plugs
are privided on front and back sides ( ref. Drg,no,95018 ) During periodic
inspection say once in 3 months open the drain plugs and drain out condensed water.

While replacing oil seals make sure that oil seals are not distorted the springs are
in their position and the lip of the oil seal is free. Apply small amount of grease to
the lip. 'V' rings can be replaced by first removing the M.S. cap.
The new 'V' ring is to be fitted such that the lip just rests against the end sheild
face. ( Execessive pressure will lead to premature failure of the 'V' ring ).
Replace the M.S. cap.

Whenever, the motor is opened and reassembled ensure that all joint faces are
properly at all joints. Recommended gasket cements : Anabond 681 of Anabond Ltd.
CENTRIFUGAL PUMPS

A. GENERAL CHECKS DURING OPERATION AND INSTALLATION

Direction of rotation

The direction of rotation of the driving member should correspond to

the direction of rotation of the pump. Wrong direction of rotation can be
injurious to the pump and hampers its performance.

Stuffing box tightness

It is good practice to check the stuffing box and see that the gland is not
too tight.

Decouple the pump and check the rotation of the drive by switching on for an instant.
Check the pump tightness. The pump shaft should be easily turnable by hand

Bearing lubrication

A constant level oiler with a clear plexiglass oil reservoir indicates the oil
reserve.

For filling the oiler, the bottle

should be swung down and should
be filled through the stem of the
bottle. As soon as it gets filled
with oil replace the bottle to its
original position and allow oil to
flow into the bearing housing.
Repeat the procedure till no more
oil flows from the bottle into the
reservoir. The required level of oil
has then been attained.
The oiler accurately maintains a fixed oil
level at the 1/3 dia. of the lower ball of both
the bearings.
Bearing Lubrication Quality: SAE 40 or equiv
Quantity: 300-600 ml
Lubricated after 200-1000 hrs of operation.

Quantity of oil required in bearing housing will be 300 - 600 ml, depending
on the model. The first replacement of oil should be after 200 hrs while
subsequent replacement should be after 1000 hrs.

Quality of oil should be equivalent grade of SAE 40 different

manufacturers as follows:

BPCL SHELL X-100-30

H.P ESSO MOTOR OIL 30/HP
H.P R.P.M PREMIUM MOTOR OIL SAE 30
CASTROL CASTOR
INDIAN OIL SERVO ENGINE
INSTALLATION

Location:

The pump should be located as near the liquid source as possible. This will
minimise the suction lift and pump will give better performance. Ample
space should be provided on all the sides for ease in inspection, operation
and maintenance.

Grouting:

After the installation is completed, the foundation bolts should be

tightened evenly and grouting may be completed. Allow about 48 hours
for setting and seasoning of the foundation.

Piping:

Piping size should be equal or more than flange size to get higher
discharge. It is not recommended to reduce the pipe size.

The piping should be air tight. Any leakage in suction pipe may drastically
affect the performance of the pump.

The suction pipe should be as short as possible for getting better

discharge. and number of bends and other fittings should be as possible to
reduce frictional losses.

Adequate supports should be provided to pipes so that its dead weight

should not fall on delivery casing completely.

The horizontal length of the suction pipe should be straight to avoid air
trapping in pipe. It should not be inclined towards the pump. Any reducer
used should be of eccentric type.

For delivery pressures more than 20 meters, it is recommended to install a

check (non-return) valve in the discharge line. The check valve placed near
the pump is to protect the pump from excessive back pressure to prevent
the water running back through the pump in case of sudden failure of prime
mover.

It is recommended to use low friction foot valve having K factor less than 0.8 for
better discharge.
Electrical Connections:

Proper earthing connection should be made at the bolts provided for

earthing. Proper size of cable should be used between supply & motor
terminals to minimise voltage drop & to carry full load current (FLC)
marked on name plate and also large enough to carry the starting current
without excessive voltage drop.

The starting current for direct on line (DOL) will be 6 to 7 times of Full Load
Current at rated voltage & 3 to 4 times of Full Load Current in Star Delta
connection.

Nuts at terminal should be tightened properly to avoid any chance of

motor burning. Cable should be without joints. No. of joints, if any,
should be minimum. Wires and connections should be properly
insulated. If not it may lead to fatal shock.

Direction of rotation

The direction of rotation of the driving member should correspond to

the direction of rotation of the pump. Wrong direction of rotation can be
injurious to the pump and hampers its performance.

Stuffing box tightness

It is good practice to check the stuffing box and see that the gland is not
too tight.

Decouple the pump and check the rotation of the drive by switching on for an instant.
Check the pump tightness. The pump shaft should be easily turnable by hand

Bearing lubrication

A constant level oiler with a clear plexiglass oil reservoir indicates the oil reserve
For filling the oiler, the bottle
should be swung down and should The oiler accurately maintains a fixed oil level at the
be filled through the stem of the 1/3 dia. of the lower ball of boththe bearings.
bottle. As soon as it gets filled
with oil replace the bottle to its Bearing Lubrication Quality: SAE 40 or equiv
original position and allow oil to Quantity: 300-600 ml depending on model.
flow into the bearing housing. First Lubrication after 200 hrs of operation.
Repeat the procedure till no more Subsequant Lubrication after 1000 hrs of operation.
oil flows from the bottle into the
reservoir. The required level of oil has then been attained.
Options to SAE-40: BPCL SHELL X-100-30
H.P ESSO MOTOR OIL 30/HP
H.P R.P.M PREMIUM MOTOR OIL SAE 30
CASTROL CASTOR
INDIAN OIL SERVO ENGINE
PUMP PRIMING

Under suction head conditions

In case of gravity feed, the pump
can be filled by opening the valve
in the inlet pipe. Venting is effected
by opening the discharge valve for
a short while.
Under suction lift conditions
Before starting, the suction pipe
the pump can be filled by
evacuating air with vacuum pump
(with closed discharge valve) or
by pouring the liquid through the
funnel fitted to the pump inlet.
Starting pump working under vacuum:
- Close Discharge Valve & Sample Valve
- Open Suction valve & Priming line valve
leading to vacuum system.
- Liquid under vacuum will get sucked in the
pump casing.
- Start the pump.
- Liquid will pump through Priming line
- Check this through Sample valve.
- Open Discharge valve.
- Close Priming line.

PUMP STARTING

Insufficient priming

If the head does not rise adequately, stop the pump and prime it again.

Regulating the delivery

Once the operational speed is attained, open the discharge valve until the
required flow and head are obtained. The delivery can be increased as
long as the motor is not overloaded.

External sealing and flushing connections

Check that the necessary external sealing and flushing connections

correspond to the existing shaft sealing arrangement.

Operation with closed discharge valve

Running of the pump with closed discharge valve for long time should be
avoided as it can lead to heating up of the pump and subsequent
damage.

Higher specific gravity of the pumped liquid

If the specific gravity of the liquid to be pumped is higher than designed,

ensure that the motor will not be overloaded.

Higher capacity

If the capacity is greater than designed ensure that suction lift is not too
high or suction head is sufficient
 Watching the conditions of operation

During operation, check the liquid level in the pump and the total head.
Connections are provided (when requested) for the corresponding instruments
on the inlet and discharge of the pump (on delivery of the pump from the
factory, the connections are sealed with screwed plugs).

Permissible bearing temperatures

The bearing temperatures can rise 50 C above the normal room temperature,
however, it should not be higher than 80 C.

PUMP STOPPING

Sequence of closing of control valves

In the absence of a check valve close the discharge valve. If the pump
is delivering from a vessel under vacuum, close the valve in the balancing
line. If the shaft sealing is with stuffing box and external sealing do not
disturb this.

Suction end control instrument

If the suction end control instrument is not provided with a pressure relief
valve, close the isolating valve.

Motor

Switch off the motor.

PUMP RESTARTING

Before restarting, check that the

shaft is stationary and not
rotating in the opposite direction.
The pump might turn in the reverse
direction due to the return flow, if
the discharge valve is leaking.
Hasty restart can damage the shaft:
Switching on during reverse rotation can
damage the shaft.

LONG SHUT DOWN

During long shutdown, the delivery medium might change the

concentration, crystallise or soilidify. Therefore, the pump is to be drained
and flushed with a suitable liquid.
MAINTENANCE

General

The pump shaft should run without vibration. The suction lift and head
conditions should not be disturbed due to changes in the level of the liquid
of the supply vessel. Do not overload the motor above the power given
on the name plate.

Shaft Sealing

Leaking stuffing box

Excess leakage at the stuffing box during the early period of operation
stops itself after the run in time. If necessary, tighten the gland nuts. Avoid
excess tightening. There should be a slight leak at the stuffing box to carry
away the frictional heat generated at the packing.

Leakage too great

If the leakage is too great and tightening does not help, the packings
should be renewed because they might have lost their elasticity.

Replace the packing

Slide back the deflector (if fitted) away from the stuffing box towards the
bearing cover.

Remove the nuts and push back the gland towards the bearing cover.

Remove the packings and the lantern ring from the stuffing box and clean
the latter thoroughly.

If the surface of the shaft sleeve indicates severe scoring it is to be

replaced.

If ready-formed packing rings are not available, cut sufficent lengths

from new packing roll. Form them into end of the rings should be cut at
an angle to the axis of the shaft.

If soft packing rings are avilable, cut them at an angle, deform them, slide
them over the shaft and form them into rings carefully. It is preffered to
have a gap of 1 mm between the ends of rings. Stagger the joints of the rings.

Tighten the gland nuts uniformly until resistance to turning of the shaft
is felt. Once again, loosen the gland and retighten.

Cooled Stuffing box

Pumps for handling volatile liquids should have cooled stuffing boxes
so that the packings do not run dry due to vaporization of the liquid.
TROUBLE-SHOOTING OF PUMPS

PROBABLE REASONS FOR TROUBLES TROUBLES

Bearing temp too high

Intermittent delivery

Pump stops. Jams

Poor or no suction
Capacity too low

Noisy operation

Power too high

Head too low.

Pump leaking
Speed too low A A
Casing or shaft-sealing leaky B B B B B
Foot valve or suction pipe leaky B B B B
Suction lift too high or suction head too low C C C C C C
Viscosity of the delivery liquid too high D D D
Specific gravity of the delivery liquid too high D
Improper installation or strain on the pump E E E E E
Loose or jamming parts in the pump F F F F
Wear rings clearance too bad due to wear G G
Wrong direction of rotation H H
Discharge line friction loss too high I
Improper lubrication J J
Pipes and/or fittings clogged or crusty K K K

CLEARING THE TROUBLES:

A Check frequency & voltage; if needed, consult EB.

B Ensure if the trouble is caused by the casing, Shaft sealing, suction pipe, foot valve or suction strainer.
Accordingly: Renew the gaskets on the casing, Tighten the gland or renew the packing rings, Ensure the
leak tightness of the suction pipe, Check the leak tightness of foot valve, Clean the suction strainer.
C Clean the suction pipe, foot valve & suction strainer. If needed, replace the flange gaskets jutting out into
the pipe. Check the suction pipe. If the temperature of the delivery liquid is higher than assumed, reduce
the suction lift or increase the inlet head.
D Pump model and motor rating are determined on the basis of data given in the purchase order.
Troubles arising due to different data can be cleared only by consulting the pump supplier.
E Readjust alignment of pump and motor. Check that no strain is transmitted to the pump by piping &
flange connections.
F Disassemable the pump and replace the defective parts.
G Replace the wear rings.
H Interchange the phase connections of the motor.
I If the piping cannot be changed in order to reduce the pressure loss, a pump with a higher head should
be installed. Consult the pump supplier.
J Fill up the reservoir of the constant level oiler.
K Clean or replace the piping and/or fittings.
WATER-RING VACUUM PUMP

OPERATION

Starting

1. Turn the shaft by hand.

2. Start the electric motor.

3. Slowly open the main watercock.

Care required during Operation

1. Regulate the quantity of water by Regulate water rate strictly:

means of valve to to the desired
flow rate at pressure of 1 kg/cm2g . Excessive water pressure is dangerous

2. Check up stuffing boxes. Small loss of water permissible. Tighten up

stuffing boxes, if required.

3. For high vacuum pumps: If the pump starts rattling at the high vacuum,
the vent cocks on the sides of the casing covers are to be slightly
opened.

Stopping

1. Close the main water cock.

2. Stop the electric motor.

3. In case of danger of frost, remove both the screw plugs on the lower
casing. In case the pump is likely to be stored for a long period,
water should be drained from it completely by opening both the
screw plugs on lower casing cover.
FACTORS AFFECTING PERFORMANCE

1. Barometric pressure.

High vacuum pumps are designed to achieve a vacuum of 28" Hg with

water entry temperature of 95 F and barometric pressure of 29.9" Hg.

Low vacuum pumps are designed to work at vacuum of 24" Hg. Under
the same conditions and with blanked flange can achieve vacuum of about
26" Hg. At this maximum vacuum, the suction capacity is Nil.

2. Temperature of air / vapour / gas / water being handled.

The effect of a higher gas temperature is to raise the internal temperature

of the water seal and thus reduce the vacuum. At a particular
temperature and vacuum, the water in the water seal begins to
spontaneously evaporate taking up the full capacity of the pump and
preventing any higher vacuum being achieved.

3. Pressure of water

The performance of the machine both as regards capacity and vacuum

also depends upon maintaining the correct water pressure. This should be
atleast 1 kg/cm2g.

4. Leakages arising from worn out automatic drain valve, control

disc rubber.

Leakages in the automatic drain valve and gland packings and suction
piping have the effect of allowing the external air to enter the system thus
limiting the vacuum.

5. Excessive internal clearances between the impeller and the

control disc following upon the incorrect selection of the side
cover packings.

Excessive clearances between the control disc and the impeller, damaged
rubber balls in the control disc or insufficent water pressure have the
effect of altering the compression ratio of the machine thus resulting in
inadequate vacuum.

6. Back pressure in the exhaust silencer-cum- separator.

Back pressure in the silencer as a result of the outlet being clogged or

not open to atmosphere, alters the working comperssion ratio of the
machine and hence limits the vacuum.
7. Incorrect selection of capacity.

Incorrect selection of capacity result in inadequate or too high vacuum

under working conditions. It may be noted that the suction capacity of the
pump as measured at the suction flange varies according to the vacuum.
If the pump selected is large for system, the vacuum may rise above the
desired level. If it is too small it may fall below the desired level.

8. Miscellaneous

Pressure and vacuum gauges should be checked against master gauges,

before coming to any drastic conclusions.

Excessive scale formation or excessive water pressure will overload the

machine and lead to damage of the pump and/or the motor.
Solvent vapors may effect the rubber balls and cause unsatisfactory
operation. It is suggested that a stock of rubber balls should be kept for
replacement as and when necessary.

The correct performance will also not be obtained if the motor is

defective or the connections between starter and motor are wrong. Low
supply voltage or unbalanced voltage may also be one of the reasons.

Sometimes, water & Air pipe connections are not done properly resulting in
incorrect functioning of the vacuum pump.

TROUBLE SHOOTING

1 Vacuum Pump Does Not Develop Sufficient Vacuum

When water pressure is maintained at 6-10 psig, the vacuum showed by

the gauge should be 28"(with a water entry temperature of 30 C and the
barometric pressure of 760 mm Hg).

Check The Gauges

In water-ring vacuum pumps, due to vibration, the vacuum gauge and water
pressure gauge may eventually not be working properly or indicating the
correct pressure / vaccum. Master spare gauges for the water pressure
and for vacuum should be used for checking the gauges mounted on the
machine. In order that the gauges work satisfactorily for a long time, they
should be mounted on a firm support or wall nearby.

Simple care saves the Gages:

Gages should be connected to the pump through copper pipes with internal bore of
4 mm so that vibration will be dampened in the pipe and the gauges will not vibrate.
 Check For Back Pressure

Discharge line of the pump should be open to atmosphere through the

exhaust silencer, without minimum of back pressure.

Quantity Of Water Regulate Water Flow-rate:

It is absolutely necessary to Less of water may cause decrease in

have the correct quantity of vacuum and also overheating of the vacuum
water circulating through the pump. More of water may cause decrease
vacuum pump while the vacuum in the displacement and increase in power
pump is on full vacuum. requirement.

Check The Vacuum Pump Cavitation

Remove the suction pipe off the suction flange. Close the two brass
cocks or small holes on the side covers. If a loud ratttling noise is heard,
due to cavitation from the pump, it is working in order and the fault lies
elsewhere.

If Cavitation Sound is Not Achieved

With closed suction port and with closed cavitation relief valves,
check whether there is any leakage of air from the automatic drain valve.
by placing a finger or thumb over the automatic drain valve opening.
If there is leakage, replace the rubber ball in the automatic drain valve.

Check that there is no excessive leakage of water from the side covers.

Check that the gland packings are not worn out. If so, replace them.

Dismantle the pump to check

o The rubber balls in the control disc are worn out. If so, replace.

o Side cover packings of the original

thickness have been utilised. If Check critically correct thickness of side
these side cover packings have cover packing
been changed during overhaul and
thicker packings substituted, the pump will not achieve required vacuum. If thinner
packings are used severe damage to the pump may result from seizure.

o Check that the control disc and side face of the impeller are not worn out
or scored.

o Check that the Shaft protection sleeves, if provided, are not

worn out.

o If Shaft protecting sleeves are not provided, check that the shafts are not
excessively worn out.
 Reassemble properly after diagnosis and correction.

These tests are to be carried out with a blanked off suction flange. In case,
the vacuum attained in service is too low, it indicates a leakage in the line or
incorrect selection of the size of the pump, or excessive temperature of
vapours entering.
2 You Hear Excessive Sound During Running

Check for cavitation

Cavitation is bad for the health of
If the pump is running at about 28" Vacuum Pump:
Hg. Check that the sound is not
due to cavitations. Check cavitation hole against choking.

Slight opening of the cavitation Continuous operation under cavitation

relief valve will stop the noise. conditions is harmful for the pump and will
The cavitation valve consist of a result in damage to impeller and pump.
small hole directly underneath the
gland packing. This may have blocked due to some dirt or dust. This
should be cleaned so that the pump works without cavitation sound.

Check for Foreign matter

Control scale Build-up:
Dismantle the pump and check
for entry of foreign matter or Excessive scale formation can permanently
broken impeller blade. Excessive damage the pump. Build up of scale reduces
formation of scale due to use of the working clearances and may eventually
hard water on the impeller and result in jamming and seizure of the impeller.
control disc may reduce the If hard water is being used, dismantle and
working clearance resulting in clean the pump regularly.
damage to the pump &
overloading of the motor. Pieces of hard deposits which have broken
loose may cause a mechanical sound. Clean and reassemble the
machine using standard clearance.

3 Motor is overloaded

Check for excessive water pressure:

Large quantities of water
enterning the vacuum pumps
through the suction line / water line
would definitely overload the
motor and possibly damage the
vacuum pump.
Check Clogged control disc ports:
Clogging is possible due to scale formation or damaged rubberballs Clean the port.
Key to efficient working of
Vacuum Pump:
Excessive water pressure can damage your
vacuum pump severely and overload your
motor.
Do not exceed 12 psig on the gauge on the
machine. If necessary, use a pressure
reducing valve.
Check for the correct distance between
the coupling halves:
Wrong aligment causes quick
wear of leather links bearings
glands. Check & correct with a
coupling gauge. Shaft should
turn freely by hand.
Start Pump in NO LOAD Condition:
Make sure the pump is drained of water
before starting, by Autodrain Valve.
Always start the vacuum pump first and
then open the water supply. NEVER start
vacuum pump after releasing the water supply.

Check the Gland packings:

Gland packings should not be excessively tight.

If after loosening the gland packings, the pump is still not freely rotating
by hand, uncouple the motor.

Check that the motor is turning freely.

Check pump bearings:

Remove the bearings and check for corrosion / foreign matter. This is
possible if the pump been standstill for a long period without adequate
protection of the bearing.

Check for Scale Formation & Pump internals:

Dismantle the pump and check for any damage to the impeller inside due
to scale formation If there is scale formation, remove it.

Check the impeller, the shaft & reassemble the vacuum pump.

Check Electrical:

Check the motor, starter, or electric supply (low or unbalanced voltage)

TOP MOUNTED LEVEL SWITCH

The Top Mounted Level Switch which goes into the tank and senses the liquid level
consists of one float and three corresponding switches.

MOUNTING AND WIRING GUIDANCE

Mount the Level Switch on the tank.

Open the Junction box of the Level Switch and connect points on Terminal Box
as under:

1&2 Wires of Level Switch-Low (LSL)

3&4 Wires of Level Switch-High (LSH)
5&6 Wires of Level Switch-Very High (LSVH)

Fix the Junction Box cover.

JUNCTION BOX
H
SV
HL 6
LLS 5
LS 34
12

NIPPLE

COUPLING

FLANGE

STEM

END STOPPER
LSVH

FLOAT

LSH

END STOPPER

LSL

MOUNTING DETAIL ELECTRICAL DETAIL

RESETTING OF DIFFERENTIAL

The differential between high and low levels can be adjusted as desired. To change the
position of the floats and corresponding switches, the procedure as follows:

Dismantling

- Cut off power supply to the instrument.

- Remove the level switch from the tank.
- Open the junction box.
- Disconnect from the Terminal Block all the wires.
- Remove the junction box by unscrewing it from the nipple.
- Unscrew the nipple.
- Remove the switch mounting assembly.

Resetting

- On the switch mounting stem, you will find two switches top one is Very High (LSVH)
Centre one is High (LSH) and bottom one is Low (LSL)
- Un-tie the switch whose position is desired to be changed, and retie at the new
position and measure with a measuring tape (Referance is the centre of the switch.)
- Insert the switch mounting stem back into the central stem, tighten the nipple and
the junction box.
- Connect the wires of the switch to the terminal block.
- Loosen the end stoppers of the corresponding float and take the float to the new
position ( at same distance and direction as that of the changed switch position
and use measuring tape.)

Checking

- Connect the terminals of a Ohm Meter to the terminals of the said switch at the
junction box terminal block.
- Now, move the float slowly on the stem, vertically up, till you get the deflection of
Ohm meter. Hold the float in this position.
- Tighten the upper end stopper of the float at 5 - 7 mm from the upper end of the float.
- Take the float up till it touches the upper end stopper. The Ohm meter should show
deflection.
- Tighten the lower end stopper at 5 - 7 mm from lower part of the float.

Mounting

- Mount the level switch back.

- Connect all the wires.
- The system is ready for use with new settings.
SCHEDULE OF PLANT PREVENTIVE MAINTENANCE
SR NO ACTIVITY F R E Q U E N C Y
DAILY WEEKLY MONTHLY QUART'LY YEARLY

1. LUBRICATION OF
Pump Bearings O
Motor Bearings O

2. TIGHTENING
Pump Gland packing O
Plant Foundation Bolts O
Coupling Bolts O

3. REPLENISHMENT/ADDITION OF
Lubricant of Pump & Motor O
Pump Gland packing O
Valve Gland Packing O

4. CHECKING ALIGNMENT
Pump O
Shaft Coupling O
Base frame O

5. OVERHAULING OF
Pumps O
Vacuum Pumps O
Steam Traps O

6. CLEANING OF
Filters/Strainers O
Flash Vessels O
Heat Exchanger Tubes O
Wash Liq. Tanks O
Conc.Liq. Tanks O
Cooling Tower Basin O
Cooling Tower Spray Nozzles O
Elec. Contacts of Starters O
Elec. Contacts of Switches O
Plant By Running On Water O

7. HYDROTESTING OF
Shell/Tubesides O
Complete Plant O

8. PAINTING O
9. INSULATION O
10. HOUSE KEEPING OF PLANT O
11. CHECKING SAFETY EQUIPMENTS O