Functional Description of the Vacuum Pump Set-1

Contents:
1. General description of the 3- stage vacuum pump set
1.1. Mode of operation of Process Vacuum -Rotary Piston Blowers
1.2. Operational description of the pump set
2. Description of principal Instrumentation and control equipment
3. Trips and alarm functions
3.1. Alarm functions
3.2. Trip functions
3.2.1.Trip functions handled by DCS control
3.2.2.Trip functions handled by HV switch gear (hard wired)
3.2.3.Hard wired- system in HV switch gear
3.2.4.Trips directly by HV- Switch gear

4. Pre-conditions for start- up

5. Initial Start- up
5.1. General requirements for start of the pump set
5.2. Safety aspect
6. Start- up step: Purging the pump set with N2
7. Operation step: From Purging to Stand- by (N2)
8. Operation step: From Stand- by (N2) to Normal operation (CO2)
9. Operation step: From Normal operation (CO2) to Stand- by (N2)
10. Operation step: From Purging to Stand- by (N2) to Stop
11. Operation step: From Normal operation (CO2) to Stop
12. Operation step: From Stand- By/Normal to Emergency Stop
12.1. Action by DCS- control
12.2. Action by HV switch gear

Remark:
The principal function of all other vacuum units is identical to unit-1
1. General description of the 3- stage vacuum pump set
The function of the pump set is based on the use of 3 single blower stages with interstage
cooling of gas in water cooled heat exchangers. Each blower stage gets cooled gas from the
intercooler and therefore will be internally cooled by so called pre- inlet cooling.
1.1 Mode of operation of Process Vacuum -Rotary Piston Blowers
Process Vacuum rotary blowers work on the basis of the well known principle of non
contact rotary pistons. Two pistons rotate in a cast iron casing without contacting one another. The
shape of their path of rotation is similar to that of an eight. The non contact operation of the rotary
pistons is ensured by a synchronous coupling via gears. The clearance between the rotary pistons
and the wall of the casing is reduced to a minimum, to ensure that only a small backflow of gas is
possible to the suction side at a defined differential pressure without the pistons contacting the
casing due to the thermal expansion of the material.
A nearly closed conveying chamber is created by the rotary pistons and gas
from the suction side will be supplied to the discharge side of the blower. The gas as at the discharge
side is cooled down in a heat exchanger and a partial flow of the cooled gas will be directed to the
conveying chamber via the pre-in-let channel. The compression is caused by the backflow of
previously compressed and cooled gas from the discharge side into the pre- inlet channel. Using this
process, the compression process is anticipated before the piston opens the conveying chamber to
the discharge side. By applying this method of a pre-compression with cooled gas the compression
heat will be dissipated by internal cooling the moment it is generated. Therefore higher differential
pressures are possible as compared to machines with no cooling system. A dry generation of
vacuum is assured.
Process Vacuum pump sets are a combination of several single pumping stages
interconnected by pipes.
The pumping stages will be driven via a coupling and an intermediate gear drive
respectively. a V-belt drive. Based on the final pressure obtained during evacuation and the
pressure relationship between the individual stages, various differential pressures exist and
consequently compression heat and mechanical losses are created which will have to be dissipated.
1.2 Operational description of the pump set
The pump set is consisting of 3 single intercooled blower stages which are con nected for parallel
and serial operation.
At each new vacuum cycle the first stage 5C6.320-1 starts to evacuate the adsorber and
discharges the gas directly to the pulsation damper 5B 6.328 via check valves on line number 500-
QR-2227-F and 500-QR-2228-F During that short time interval the pump set operates only with the
first stage up to a defined suction pressure (PR 5/92102) of approx. 600 mbar. The other two stages
operate without compression (Dp = 0).
Below 600 mbar at the inlet pipe (PR 5/92102) the actual gas flow to 2nd blower stage is
less enough that it can be taken 100 % by second blower stage 5C6.320-2. The gas directly flows to
the pulsation damper 5B 6.328 via check valve on line number 500-QR-2231-F. Check valves on
line number 500-QR-2227-F and 500-QR-2228-F have already closed at suction pressure of 600
mbar. During that pressure interval the unit is working as a 2- stage system.
Below 300 mbar suction pressure (PR 5/92102) the actual gas flow is less enough that it can
be taken 100 % by third stage blower 5C6.320-3. The gas directly flows to the pulsation damper 5B
6.328 , check valve on line number 500-QR-2231-F has closed at 300 mbar suction pressure, Check
valves on line number 500-QR-2227-F and 500-QR-2228-F are still closed. During that time the unit
is working as a 3- stage system.
A new vacuum cycle will start with a pressure of 1100 mbar abs. In order to prevent the
pump set against a to high suction pressure a possible high suction pressure will be released
directly to the outlet via check valve 500-QR-2218-F using the by-pass piping.

Cooling water supply:

The supplied cooling water must have a min. inlet temperature of 43°C to avoid condensation of
water and corrosion inside ail parts of the pump set in contact with process gas. The water
temperature switch is tripping the pumpset motor in case of a min. cooling water inlet
temperature.
A manual N2- purge has to follow in case of emergency stop.
(see interlocking list)
2. Description of principal Instrumentation and control equipment

Please refer to:

P&l- Diagram No. ES/QM2/P&ID/15905-03(11E)
Process data list 145 - DOK - 008 - SGI
Valve list 1 45 - DOK - 004 - SGI
For safe operation the described vacuum pump set is equipped with following instrumentation and
control:
 Pressure gauges at each stage to control suction and intermediate pressures in according
to P&ID as well as process data list 145 - DOK - 008 – SGI
 Pressure switch to stop nitrogen purge flow
 The gas temperature after each stage and after each cooler will be monitored by
temperature indicator TRAS 5/93104, TRAS 5/93105 TRAS 5/93107 during continues
operation. If the gas temperature exceeds the trip value listed in the Process Data List, the
motor will be stopped automatically.
 Flow switches to control the flow of cooling water to each water cooler
 Pressure transmitter (PR 5/92102) on suction side of the first pump stage will actuate
valve PV 5/92102B by transmitter signal and pressure control PRC 5/92102A to keep
suction pressure in normal range and trip in case of to low suction pressure.
When operating the pump set with nitrogen or C02 different compression heats will be generated in
each pump stage.
The compression heat during N2 operation is higher than the compression heat with CO2.
Due to max. allowable operating temperatures in the pump stages the pressure control PRC
5/92102 (consisting of suction pressure control PR 5/92102 and control valve PV 5/92102) has to be
operated with two different set points for:

Operation step: Stand- By Mode with (N21 Set point: 150 mbara
and
Operation step: Normal operation with (CQ2) Set point: 100 mbara

As well the suction pressure trips has to be changed accordingly the actual operation
step.
Generally all trips and alarms can be handled either by DCS control or by fail safe interlocking
system at HV switch gear. The Process Data List as well as the interlocking list shows which
system will handle the single trips.
Please see process data list for set points and trip points.
3) Trips and alarm functions
(Please see Interlocking list, attached to this functional description)
3.1 Alarm functions
All alarm functions are generally handled by DCS control For further information see
Interlocking list.
3.2 Trip functions
Trip functions are handled either by: DCS control or HV switch gear (hard wired)
3.1.1 Trip functions handled bv DCS control
The interlocking list describes all trip functions which are handled by DCS control as well as
the action to be done.

3.2.2 Trip functions handled bv HV switch gear (hard wired)

General purpose for hard wired functions:

Before starting and stopping the pump set the overall bypass valve must be opened from the
pressure side of the vacuum pumpset to the vacuum side in order to start with no
differential pressure. The bypass valve is also used for breaking the vacuum before stopping the
blowers.
When the vacuum has been broken by the bypass valve the motor can be stopped, This must be
done in order to prevent reverse running of the machines and to start and stop the machines at
unloaded conditions. In case of a to low suction pressure (< 65 mbar) the motor has to be stopped
to avoid over load and to high temperatures In any case of a emergency stop or power failure it is
essential that the by- pass valve SOV 5/97108 opens in any case.

In order to guarantee a fail safe function of the pump set following items are hard- wired connected.
- High voltage motor 5M 6.320

- By- pass valve SOV 5/97108

Spring to open (FO) in case of fail of electrical and/or pneumatical power

- Pump set outlet valve SOV 5/97110

Spring to close (FC) in case of fail of electrical and/or pneumatical power

- Nitrogen purge valve PV 5/92102A

Spring to close (FC) in case of fail of electrical and/or pneumatical power
3.2.2.1 Hard wired- system in HV switch gear

Within the HV- switch gear an auxiliary relay is used to connect/disconnect the

outlet of the DCS control to the solenoid valves of valves SOV 5/97108, SOV 5/97110 ,PV 5/92102A

The aux. relay is directly connected to main motor relay.

In case the motor is in operation the aux. relay connects DCS and solenoid

valves to allow direct operation from the DCS control. In case the motor stops /trips the aux. relay

disconnects the line between DCS and solenoid valve. Therefore all valves will reach their a. m. fail

position

DCS outlet
3.2.2.2 Trips directly bv HV- Switch gear
Actuated by the HV switch gear a motor trip will be directly executed in case of:
power failure of motor M 6.320
Temperature trip 93171-175 (motor temp.)
overload of motor M 6.320
Suction pressure switch PS 5/92115 (to low suction pressure)
The pressure trip of PS 5/92115 has to be integrated additionally into the
HV-switch gear