Vacuum System

PLANT ENGINEER OLEOCHEMICAL

Vacuum System
• Types of vacuum system:

Vacuum system with Vacuum system with Vacuum system combine

direct contact condenser surface condenser with liquid ring pump
Condenser
• There are 2 types of condenser:

• Surface condenser

• Direct contact condenser

Surface Condensers
• In surface condensers there is no direct contact between the vapours to be
condensed and the cooling water.

• The condensation heat is removed via the heat-conducting walls.

• The temperature difference between condensation and cooling water is

greater than that in the mixing-type condensation method.

• The separation of the two media ensures environment-friendly operation.

Surface Condensers
• The construction of a condenser will be similar to other shell
and tube exchanger, but with a wider baffle spacing.
• Four condenser configuration are possible:
1. Horizontal, with condensation in the shell, and the cooling
medium in the tubes.
2. Horizontal, with condensation in the tubes.
3. Vertical, with condensation in the shell.
4. Vertical, with condensation in the tubes.
• Horizontal shell-side and vertical tube-side are the most
commonly used types of condenser.
Direct-Contact Heat Exchangers
• Hot and cold streams are brought into contact without any separating wall,
and high rates of heat transfer are achieved.

• In direct-contact cooler-condensers the condensed liquid is frequently used

as the coolant.
Direct-Contact Heat Exchangers
• Direct-contact heat exchanger should be considered whenever the process
stream and coolant are compatible.

• The equipment used is basically simple and cheap.

• Suitable for use with heavily fouling fluids and with liquids containing
solids.
Several Types of Condenser
1. From the point of view of the means of extracting the air:
A. Wet air condensers, where the mixed air and water are extracted together.
B. Dry air condensers, where the water and the air are removed separately.
2. From the point of view of the means of extraction of the water:
A. Short condensers, with extraction by a pump.
B. Long or barometric condensers, with removal of water by gravity.
3. From the point of view of the method of air circulation:
A. Co-current condensers, in which water and air circulate in the same
direction.
B. Counter-current condensers, in which water and air circulate in opposite
directions. A counter-current condenser is obviously a dry air condenser.
Several Types of Condenser (1)
Several Types of Condenser (2)
Direct Contact Heat Exchanger
Design
• Height of the condenser

• The exchange will be more complete as contact between these two fluids is
more intimate, depend on the surface offered by the water and time of
contact.

• The are of contact depends on the course of the water, and on its degree of
subdivision.

• The time of contact depends mainly on the height of the condenser and the
number of stages or of baffles provided to break up the fall of water into
numerous small streams.
 Direct Contact Heat Exchanger
Design
• Height of condenser can be estimated from table below.
Counter-current wet air condensers to handle 650-6500 lb. vapour per hour
Without baffles H= 3-6 ft
With 1 baffle H= 3-6 ft
With 2 baffles H = 4-7.5 ft
Counter-current dry air condensers to handle 650-26500 lb. vapour per hour
Without baffles H=10 ft. at least
With 5-6 baffles H= 8-12 ft

• For barometric column with 4-6 baffles the height given in table
below.
Capacity, lb. vapour/h 1,100 11,000 44,000 220,000
H(ft) 5 8 10 20
 Direct Contact Heat Exchanger
Design
• Cross-section of the condenser
Cross-section will depend directly on the quantity of vapour to be condensed. Cross-section can be estimated
from table below.
Co-current wet air condensers
Without baffles S = 1.2Q sq.ft.
With 1 or 2 baffles S = 2Q sq.ft.
Counter-current dry air condensers
Without baffles S = 1.65Q sq.ft.
With baffles S = 2.2Q sq.ft.
For small capacities, below Q = 2t/h.
Vapour to be condensed lb/h Diameter of body (inches)
Without baffles With baffles
650 16 20
2200 22 24
4400 28 30
 Advantages and Disadvantages of
Condenser Types
Condenser Types Advantages
Direct Contact Condenser • The construction is simple
• Installation and maintenance cost is
low
• It requires less floor space when
compared to the surface condenser
• The mixing of vapour and condensing
medium reduces the amount
condensing medium required
Surface Condenser • Condensate is free from impurities. It
can recirculate to the system
• Since there is no mixing, cooling
medium (water) of poor quality can be
used. This advantage reduces the cost
of water treatment
• Cooling of condensate can be easily
controlled by regulating the flow of
cooling medium
• Suitable for large plants
• Greater plant efficiency
Disadvantages
• Not suitable high capacity plants
• Wastage of condensate. If condensate
is to be recirculated to the system, the
condensing medium should be free
from harmful impurities
• If the condensate extraction pump
fails, there is a greater possibility of
flooding of condenser
• Capital cost and maintenance cost are
high
• Surface condenser is bulky compared
to the jet condenser
• Leakage and fouling of cooling
medium pipeline
• Need more cooling water (cooling
medium).
 Liquid Ring Pump

Troubleshooting Rotary Vane Pump

Dry Screw Pump

Liquid Ring Vacuum Pump
Common Problems :
• Sealant Vapor Pressure is too
high
• Incorrect sealant flowrate being
supplied
• Process Contamination of sealant
• High Horsepower
• Leakage
• Noisy pump operation
• Vibration problem
Liquid Ring Vacuum Pump
Sealant vapor pressure is too high

• The lower the temperature of the

sealant, the lower its vapor pressure,
resulting in increased pumping capacity
and deep vacuum performance

• The vapor pressure (Pv) of the sealant

at operating temperature should be less
than half of the required vacuum level
(P1) as measured at the pump inlet

• As the process vacuum level approaches

the sealant’s vapor pressure
the sealant will begin to flash from the
liquid to the vapor phase (cavitation)
Liquid Ring Vacuum Pump
Incorrect Sealant Flowrate

1. Too much sealant is supplied

• If too much sealant is fed to the

vacuum pump, the volume of the
liquid ring within the pump will
increase. Subsequently the
volume of the rotor available for
the pump to move process gas will
be displaced and the pump will
lose pumping capacity, resulting
in a loss of
vacuum
Liquid Ring Vacuum Pump
Incorrect Sealant Flowrate

1. Too little sealant is supplied

• If too little sealant is fed to the

vacuum pump, the liquid ring
volume will be reduced and the
liquid ring will no longer be able
to create the necessary seal
between the rotor and the
housing allowing internal “slip” of
the discharge gas back to suction,
resulting in reduced pumping
capacity and loss of vacuum.
Liquid Ring Vacuum Pump
Process Contamination of the Sealant (in full sealant recovery systems)

Condensable carry-over - During the process of moving gases from the vacuum
chamber through the
liquid ring pump, the process gas will contact the sealant and may subsequently
collect in the sealant. If the substance collects in the sealant liquid and
has a vapor pressure higher than the sealant, the substance will enter the liquid
ring pump and flash from the liquid to the vapor phase and reduce
the pump’s capacity. As an example, when using oil as the liquid ring sealant, if
water vapor is a carry-over product from the process gas, the vapor will
condense to liquid in the discharge separator tank and effectively increase the
pump sealant vapor pressure and reduce capacity.
Particulate carry-over – Particulate carry-over or other matter may clog sealant
piping, strainer, heat exchangers, valves, etc. and restrict sealant flow
to the vacuum pump resulting in reduced pumping capacity and possible
overheating of the liquid ring pump.
Liquid Ring Vacuum Pump
High Horsepower

Probable causes are:

o V-belt misalignment and improper tensioning of the belts.
o Pump is severely overloaded with water.
o Restriction at the pump inlet or pump discharge
o Motor problem
o Pump running at a speed above the required speed.
Liquid Ring Vacuum Pump
Leakage

Most likely areas of leakage are:

o Gland packing area - It can be resolved by tightening the packing and if
leak still persists,replace the packing.
o Leakage at body gasket – Torque the body bolts evenly, if leak does not
stop, then replace the body gasket.
o Leakage at the body plugs – Tighten the plugs. If leak still persists, check
for corrosion on plug threads and body threads. Replace plug if corrosion is
severe.
o Leakage through castings – Causes can be erosion, corrosion or insertion
of a hard object into the pump
Liquid Ring Vacuum Pump
Noisy Pump Operation

Noisy pump operation could be due to:

o Foreign object trapped into the pump – This is a very serious case and
is usually accompanied by erratic noise and vibration.
o Pump severely overloaded with water – Causes groaning and hydraulic
noise.
o Cavitations – Sounds like marbles in the pump.
o Bearing noise – Possibility of bearing failure.
o Lots of carryover to the pump – This is accompanied by high horsepower.
Liquid Ring Vacuum Pump
Vibration Problems
Intermittent vibration

• Check for liquid slugs or carry-over from separator.

• Check for low pockets in inlet piping where liquid can accumulate and burp
over into the vacuum pump at irregular intervals.

• Check for irregular sources of vibration originating. Piping or separators can

be the source of vibration if they are not properly secured in place or
supported
Liquid Ring Vacuum Pump
Continuous chronic Vibration

• Look for constant carryover and / or excessive seal water to the pump.

• Look at discharge piping or level indicator to be sure that the pump is not
operated when in flooded condition.

• Check coupling or V-belt alignment and tensioning.

• Make sure pump is not started against blank suction subjecting it to

immediate high vacuum.This does not allow the ring to form properly.

• Check pump mounting and alignment. Loose feet, improper shimming,

resonating bases and improper grouting can set up unwanted vibrations.

• Check bearings and lubrication and replace failed bearings.

Rotary Vane Vacuum Pump
Pump doesn’t start

• Connect the pump correctly, if not connected

properly

• Set motor protection switch properly, if

incorrectly set

• If operating voltage does not match with

motor, replace motor

• Replace motor if motor is malfunctioning

• If oil is too vicious – Use appropriated oil grade

• Exhaust filter / exhaust line is clogged, replace

filter or clean exhaust line
Rotary Vane Vacuum Pump
Pump does not Reach Ultimate Pressure
• Gauge is unsuitable – Use correct gauge
• External leak – pipe fittings may be loose.
Check and tighten all fittings
• Float valve does not close – Repair the valve
• Inadequate lubrication due to unsuitable or
contaminated oil clogged oil filter or clogged oil
lines – Change oil replace filters or clean Oil
line ad casing.
• Vacuum lines are dirty – Clean vacuum lines
• Pump capacity is too low – Check required
pump capacity, and replace the pump if
necessary
Rotary Vane Vacuum Pump
Pumping Speed is too Low

• Dirt – trap in the intake port is clogged –

Clean the dirt-trap. Make sure that dust filter
is installed in the intake line.

• Exhaust filter is clogged – Install new filter

elements

• Connecting lines are too narrow or too long –

Use adequately wide and short connecting
lines

• Anti-suck back valve is hard to open – Check

spring for free length.
Rotary Vane Vacuum Pump
Pumping Speed is too Low

• Dirt – trap in the intake port is clogged –

Clean the dirt-trap. Make sure that dust filter
is installed in the intake line.

• Exhaust filter is clogged – Install new filter

elements

• Connecting lines are too narrow or too long –

Use adequately wide and short connecting
lines

• Anti-suck back valve is hard to open – Check

spring for free length.
Dry Screw Pump
Insufficient Pumping Capacity

Probable causes:

• Suction filter or strainer is clogged –

Clean or change it
• Too much Clearance – Check
clearance
Dry Screw Pump
Overheat

Overheating of the pump could be due to:

o High temperature at vacuum pump inlet

– Reduce inlet temperature
o High compression ratio – Check suction
and discharge pressure
o Problem with cooling water flow – Clean
cooling water line
o Discharge port or line is clogged and back
pressure is increased – Drain and clean
discharge
port and line
Dry Screw Pump
Damaged Bearing or Gear

Probable causes:
o Improper Lubricant – Change Lubricant
o Lubricant level low – Refill lubricant
Case Study
Possibilities that can cause vacuum problem in SN 3 :

• Leakage in the system – tracing line

• In low pressure region within ejector, vapor is condensed increasing

pressure drop – cleaning ejector

• Incorrect sealant flow rate being supplied

Case Study Finishing

Soap condense at the top of Vacuum pump

cyclone overflow is clear