PREMIER

INSTALLATION
AND
OPERATION MANUAL

LIQUID RING VACUUM PUMP MODEL

PVL20/PVM20/PVH20

5902 Bluff Road, Boaz, AL 35956.

Ph. No. (304)250-7078, (678)778-2046 Fax : (256)438-5050
E-mail : vtummala@premierpumps.net www.premiervacuumsys.com

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 PREMIER
PREMIER VACUUM SYSTEMS
5902 Bluff Road, Boaz, AL 35956.

Pump Model :PVM-20 Serial No. :SSR020

WARRANTY

We warrant that the pump supplied by us is free from defective material and
faulty workmanship. This warranty holds good for a period of 24 months from
the date of commissioning. Our liability with respect to any complaint is
limited to replacing part/parts free of charge ex-works or repairs of the
defective part/s only to the extent that such replacement/repairs are attributable
to or arise solely from faulty workmanship or defective material.

This warranty holds good only for the products manufactured by us.

For PREMIER VACUUM SYSTEMS LLC.,

Venkat Tummala

Date : February 13th 2013 DIRECTOR

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 CONTENTS

1 GENERAL
2 HANDLING
3 PRINCIPLE OF OPERATION
4 INSTALLATION
5 OPERATION
6 SWITCHING OFF
7 TROUBLE SHOOTING
8 MAINTENANCE
9 PARTS LIST
10 SKETCHES AND DRAWINGS

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 1 GENERAL

1.1 Receiving and storage :

On receiving check the contents of the packing with the packing list sent
with the pump. Any loss or damage should be brought to the notice of the
transporter and insurer with a copy to us.
Store the pumps and its accessories at a safe place where there is no danger
of solid material and debris entering interior of the pumps and other parts.
Protective covering on inlet flange, outlet flange which are fixed at our
factory should not be removed till the pump is installed and is ready for
connecting to the piping. If solids enter the pump and are not removed the
pump will be damaged when put under operation.
1.2 TEST :
Every pump is subjected to a performance test on our works test bed before
dispatch. The pump is cleared for dispatch only after attaining the operating
conditions guaranteed by us. By observing the instructions given herein, the
pump will give trouble free operation and meet the specified operating
parameters.
1.3. NAME PLATE :
Each pump is provided with a name plate fixed on the body. While ordering
spare parts please quote the pump Sl.No. pump model, the description of the
part and part no. as given in the parts list.
2. HANDLING
Pumps should be handled with utmost care. While lifting the pump either in
the packed/unpacked condition, use nylon or jute rope and avoid the use of
steel rope. Project paint coating by providing felt padding under the rope at
the contract points. The pump should hang upright with its weight
distributed evenly and avoid shock at all events. Please refer Fig 1 for lifting
arrangement.

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 LIFTING AGREEMENTS

5
2.1 WEIGHT OF PARTS :

The weights of the pump, its heavy parts and accessories are given below. The
weights are approximate and will be helpful for selection of suitable lifting
tackles.

BASE PUMP - 380 Kgs/838 Lbs

BODY - 100 Kgs/220 Lbs
HEAD - 75 Kgs/165 Lbs
CONE D.E / I.E - 8 Kgs/17.6 Lbs
ROTOR - 70 Kgs/154 Lbs
SHAFT - 27 Kgs/60 Lbs
BEARINGS - 6 Kgs/13.2 Lbs

2.2 CAUTION :

Read these instructions carefully and follow them before any attempt is made
to install, operate and repair the pump. If difficulty is experienced contact us
immediately for assistance.

1. Do not run the Pump, unless the pump is first connected to a continuous
supply of clean seal liquid/water. Dry running will overheat the gland and
shaft, and may damage the pump.

2. Use a strainer in seal liquid/water line to prevent any foreign material from
entering the pump.

3. While connecting the pump to a new system use a perforated sheet or a wire
mesh as a strainer in the suction line flange joint as near the pump as possible
to prevent pipe scale, welding shots, metal chips and other foreign matter that

6
 may be lying in the piping from entering the pump. This strainer should be
removed from the piping after a week of operation.

4. When seal liquid is water, and is hard, excessive deposit of scale may form on
the surface of the parts and the rotor may bind on the cones. Regularly clean
the internal surface free of the scale by flushing the pump with scale removing
agents.

5. Operation of pump at high vacuum or low absolute pressure on the suction

side may result in noisy running of the pump due to cavitation in the seal
liquid/water and the life of the pump deteriorates. Pump should not be
operated at such high vacuums.

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 3. PRINCIPLE OF OPERATION
Premier PV series liquid ring vacuum pumps and compressors are rotary
machines in which liquid is made to act as piston. A balanced cylindrical rotor
with hollow hub and a series of curved blades projecting radially, turns freely
in a cylindrical casing which is larger in diameter than the rotor. The blades of
the rotor are enclosed at the sides thus forming a series of buckets, open at the
bottom into the hollow center.

In operation the casing contains sufficient liquid, usually water, which when
carries around the periphery of the casing by the rotor blades, forms a solid
ring of liquid inside the casing, due to centrifugal force, since the rotor is
smaller in diameter than the casing and rotates on a center eccentric to that of
the casing. It will be seen that during part of the cycle of rotation the rotor
buckets are entirely filled with liquid, and during part of the cycle, as the
liquid recedes into the casing, the rotor buckets will be partially empty.

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 The liquid alternately entering and clearing the rotor buckets at high speed
constitutes a series of liquid piston that surge in rapid succession in and out of
the rotor buckets. Air enters through the inlet ports of the cone which are
located at the point where the liquid surges away from the rotor (A) and into
the casing. Discharge ports are at the point in the rotating cycle where the
liquid again surges back into the rotor buckets, permitting the compression and
discharge of air. This effect is continuous and is repeated thousands of times
per minute, producing an un-interrupted air flow without pulsation/vibration.

When the inlet is connected to a closed system and the outlet to atmosphere
the machine will draw air and gases from the system discharges into the
atmosphere and will act as Vacuum pump. When the inlet is connected to the
atmosphere and the outlet a closed system the machine will draw air from the
atmosphere and discharges into the system and will act as Compressor.

The liquid ring acts not only as a piston to compress the gas/air but also
absorbs the heat produced due to compression, friction and any latent heat
from vapor condensation occurring.

4. INSTALLATION

Prepare a plain cement concrete or reinforced cement concrete foundation for

the pump and the driving motor as shown in the layout drawing at-least two
weeks before the erection of the pump. The depth of foundation, the strength
of foundation should be such that it with stands the load imposed on it by the
pump and motor and the belt tension. Leave pockets for the foundation bolts
and an allowance of about 40mm in the height of foundation for filling it with
cement grout at the time of erecting the pump. The pump is supplied along
with two C.I. skids fitted to its feet by four bolts. Generous allowance is
provided on the diameter of holes drilled in the pump feet for the bolts to pass.

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 Place the pump along with skids and foundation bolts on the foundation and
level the pump by placing steel shims under the skids as near to the foundation
bolts as possible. Grout the foundation bolts and CI skid. After 3-4 dayes fix
the ‘V’ Belt pulley on the pump. Fix the slide rails along with foundation bolts
to the feet of the motor and the ‘V’ Belt pulley on the motor shaft. Ensure that
the slide rails and the face of the motor, ‘V’ Belt pulley are parallel to one
another. Grout the motor slide rails along with their foundation bolts after the
motor and pump-pulleys are brought into alignment and their centre distance is
as indicated on the layout drawing. The ‘V’ pulley is light interference fit on
the shaft. Do not drive the pulley on the shaft by hammering it as this will
transmit the hammer blow to the idle end bearing and might damage it. Fix the
two mounting studs on the end of the pump shaft as shown in the sketch (fig.2)
and by tightening both the nuts uniformly mount the pulley along with the cap.
After removing the studs fix the cap to the pulley by tightening four socket
head cap screws.

4.1 PIPING :

The weight of the piping connected to the suction and discharge manifold
flanges should not be allowed to come on the pump. The piping should be so
supported that in the absence of tightening bolts on the manifold flanges, the
pipe line stay in line with the manifold flanges. Once this is ensured tightening
the flange bolts will not distort the pump as pipeline load will not be
transferred to the pump.

The pump handles considerable quantity of liquid along with air/gases, hence
gradual slopes should be provided in the piping for the smooth flow by gravity
of any liquids entering the pump. For this reason, suction side piping should
slope downwards the pump, and the discharges side piping should slope
downwards away from the pump. When the liquid entering along with the
incoming gases is more, separator, with arrangement for removing the liquid

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 from the system before it enters the pump should be provided. Details can be
had from us when required.

Pipe line interior should be free from rust, scale deposits, weldshots, weld-
slag, cut-pieces of metal and other solids like bolts, nuts, washers when they
are installed. The perforated sheet or wire-mesh supplied along with the pump
fitted to the suction manifold flange should remain in the piping for atleast a
week after the initial start up of the pump.

The nominal sizes of the pipe lines should be atleast equal to or larger than the
sizes of the pump inlet nozzles. The pump has two inlet flanges are connected
in parallel by the inlet manifold. Out of the four outlet flanges one set of two
flanges is on one side and the set of other two is on the opposite side of the
pump. For normal operation two flanges of any one set are connected in
parallel by outlet manifold and flanges of other set are blanked. The outlet
manifold can be connected to any one set for ease in piping layout.

The construction of pump lends itself for operation on two different vacuum
duties each requiring half of the pumps normal capacity. It can thus be
operated as two independent vacuum pumps of half the capacity. The Capacity
vs. Vacuum characteristics of each half will be identical to one another. Both
the halves can be operated at different vacuum levels without one affecting the
operation of the other appreciably. For such operation the suction and
discharges manifolds are not used and the two suction flanges are connected
separately to the two individual systems and the corresponding discharge
flanges are connected to individual water separators. Details for such use can
be had from us when required.

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 4.2. SEAL LIQUID/WATER SUPPLY :

Connect the “Seal Water Inlet” (shown on the layout drawing) to constant
source of cool, clean water. One strainer, Two valves and a water pressure
guage should be arranged in the water supply line. The strainer will prevent
solids from entering the pump along with the water. It should be checked at
regular intervals and cleaned. Out of the two valves one is a shut-off-valve and
is used for either fully opening or fully closing the water supply to the pump,
before starting or after stopping the pump respectively. The other valve is a
regulating valve and is used for regulating the water entering the pump for its
optimum performance. Once this valve is adjusted for the optimum
performance of the pump its setting is not disturbed.

Refer to the table for requirement of seal water at different levels of vacuum
and speed.

Seal water requirement for operating Vacuum

Below 500 mm Hg. Above 500 mm Hg
Pump Speed
890 RPM 40 LPM 50 LPM
980 RPM 52 LPM 64 LPM
1070 RPM 65 LPM 80 LPM

Seal Water Flow Rates:

PVL-701 10 GPM , 38 LPM

PVM-702 20 GPM, 76 LPM
PVH-703 18 GPM, 68 LPM
The pressure gauge will indicate the pressure of water entering the pump at the
seal water inlet. This should be around 0.5 to 0.8 Kg/cm 2. The seal water should
be supplied at a higher pressure than this to compensate the pressure drop in
strainer, valve and supply line. A rotameter/flow indicator of a suitable flow
range may be installed in the water line to indicate the actual flow rate of water
flow.

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4.3. DRAINS:

At the bottom of the pump body two tapped holes fitted with plugs are located.
The seal liquid can be completely drained from the body through these holes
when the pump is shut-off. By fixing a length of pipe with a valve in these
tappings, part of the seal liquid can be continuously drained from the body while
the pump is in operation. This is helpful in draining large quantities of water
entering the pump at the suction and flushing the interior of the pump for any
foreign material entering the pump while in operation. One drain plug of is
located on each head through which liquid from inlet passage can be drained
when the pump is shut-off.

4.4 STUFFING BOX PACKING:

On both the ends stuffing boxes are packed with graphite Asbestos packing rope.
While repacking see that the joints of all the rings are not in one line. The gland
nuts should be only tightened slowly and uniformly when the pump is running to
reduce the leak from the gland to a constant dripping which will ensure gland
cooling, to prevent burning of packing and scoring of shaft.

4.5. BEARING – LUBRICATION:

The pump has two identical bearings, one on each end. The bearings are
lubricated by “Castrol” LM all purpose grease before the pump is tested and
shipped from our works. Relubricate after every three months of operation. After
an year of operation remove the bearing covers and inspect the condition of
bearings and grease. If grease appears contaminated clean the bearing with
solvent and with light lubricating oil. Then repack the interior of the bearing full
and the bearing covers half full with grease and reassemble the covers. Follow
the instructions issued by reputed bearing manufacturers on bearing maintenance
and replacement.

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5. OPERATION
Before starting the pump check the following:
1. The pump should rotate freely by hand
2. The direction of rotation of driver should correspond to the direction arrow
fixed on the pump.
3. Pump pulley and motor pulley are in proper alignment.
4. Belt tension is properly adjusted.
5. Belt guards are inplace (optional).
6. Seal water is available at required pressure.
7. Perforated sheet or wire mesh supplied with the pump is in suction line as near
to the suction manifold as possible.
Open both the valves in seal water line and allow the water to flow into the
pump. Open the drain plugs at the bottom of the body and see that seal water
flows freely out of the pump and then close the drain plug.

Start the driving motor, Check the speed of the pump, and the motor current
and compare with the specified values. Check the temperature rise of bearing
housing at regular intervals of 15 minutes during the first two hours of
operation. If the temperature does not stabilize below 70 0C stop the pump and
investigate.

5.1. ADJUSTING SEAL LIQUID/WATER FLOW:

For every condition the optimum quantity of seal water can be adjusted as
described below.

Fully open both the valves in the water line. While watching the vacuum
gauge gradually close the adjusting valve till the vacuum starts to fall. Now
slightly open the valve to maintain the maximum vacuum and no more.
Excessive seal water though not harmful for the pump will reduce the pump’s

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 capacity to handle air and increase the power input to the pump. The setting of
adjusting valve should be left without disturbing and the shut-off-valve should
be used for fully opening or closing the water supply to the pump before
starting or stopping the pump.

6. SWITCHING OFF

6.1 Stop the pump immediately, if any defects are detected. Don’t start the pump
unless the defects are rectified. Report immediately to our works, if it is not
possible to rectify the defects. Stop the cooling water supply.
6.2 If the pump is not required to be operated for a long time, drain the casing
completely. If the pump is required to be stored for a long time, the bearings
have to be removed and cleaned with solvents after taking out the grease. The
pump bearing housing should be dried internally with hot air and should be
flushed with moisture free protective such as light oil or kerosene. Besides
this, used oil may be poured inside the pump through heads inlet while
rotating the rotor so that protective film is available inside the pump
safeguarding against corrosion.

7. TROUBLE SHOOTING

The pump is simple in construction and has only one moving assembly of
rotor with shaft. It hardly needs any maintenance except for the lubrication of
bearings. If at any time trouble is experienced in obtaining the specific
discharge and vacuum, the following points should be checked before deciding
to dismantle the pump.
1. Failure of seal water: Required vacuum cannot be obtained and
maintained without proper quantity of seal water. Check for blocked water
supply line, or chocked strainer.
2. Improper direction of rotation: After servicing, the motor might have
been connected for reverse rotation.

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 3. Improper assembly: If dismantled previously the parts might not have
been assembled in their original places.
4. Leakage in the system: New leaks might have developed in the system
thereby increasing the discharge rate and lowering vacuum obtained.
5. Hot sealing water: Cooler the sealing water higher the maximum vacuum
that can be obtained. Above 300C the shut off vacuum will fall rapidly with
increase in seal water temperature and rise in vapor pressure of water.
6. Restriction in suction and discharge piping: Blocked suction and
discharge piping will reduce the capacity of the pump.

MAINTENANCE
8.1 Running Clearance between rotor and cones:
For efficient operation of the vacuum pump the rotor which does not touch the
cones runs with a predetermined running clearance between its conical bores
and conical surface of the cones. These clearances are sealed by the seal water
present inside the pump. As this clearance can be easily felt and measured
after the pump is assembled it is given in terms of free axial movement of
rotor with respect to the cones. By moving rotor and shaft assembly axially
from one extreme end i.e., when the rotor touches the idle end cone to the
other extreme and when rotor touches the driving end cone the free axial
movement can be measured. Refer to table for axial play.

AXIAL PLAY

Pump size PV-10 PV-20 PV-30 PV-45 PV-60 PV-90 PV-120 PV-180 PV-270
Min 1.0 1.5 1.5 2.0 2.0 2.5 3.0 3.0 3.0
C.I. Max 2.5 3.0 3.0 3.0 3.0 3.5 4.0 5.0 6.0
Min 2.0 3.0 3.0 3.0 3.0 4.0 4.0 4.0 5.0
S.S Max 3.0 4.0 4.0 4.0 5.0 6.0 6.0 6.0 8.0

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 8.2 Measuring Free axial movement of rotor:
The running clearance, expressed as free axial movement of rotor, set at the
works may increase due to corrosion and erosion after long continuous use and
result in a reduced capacity of the pump. The pump should be dismantled for
adjustment of clearance. If the loss of material due to corrosion and erosion is
uniform the clearance can be reduced by adding jointing/packages between
cones and heads. At any time to measure the running clearance (free axial
movement of rotor) proceed as follows. Refer to sketch showing idle end
bearing arrangement (Fig.4) and the cross section of pump.

The Idle end bearing inner race is held on the shaft by a lock nut and lock
watcher. The inner bearing cover, the outer bearing cover and the outer race of
bearing cover and the outer race of bearing are held together by three long
studs marked ‘A’. The thickness of shims/spacer in gap ‘D’ determine the
position of rotor, shaft and bearing assembly in relation to the cones and heads
of the pump and three screws marked ‘B’ fix the bearing assembly in this
position. Three screws marked ‘C’ fitted on the outer bearing cover are used

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 for moving the rotor assembly towards the idle end for measuring the axial
movement.

Remove the idle end bearing cover and shims/spacer after removing screws
‘B’ and nuts from the studs ‘A’. Replace the idle end bearing cover without
the shims/spacer. See that the packing between the bearing cover and bearing
outer race is in its position. Tighten the nuts on studs ‘A’ but do not fix the
screws ‘B’. While turning the rotor and shaft assembly by hand gradually
tighten the three screws marked ‘C’ uniformly to move the rotor and shaft
assembly towards the idle end cone until the rotor touches the idle end cone
and binds slightly. Measure the gap between bearing cover and housing and
call it D1. Remove screws ‘C’ from bearing cover and introduce screws ‘B’
and uniformly tighten them. The rotor which was touching the idle end cone
earlier will now move towards the driving end cone and will be free to rotate.
While turning the rotor and shaft assembly by hand gradually tighten screws
‘B’ until the rotor touches the driving end cone and binds again slightly.
Measure the gap between bearing cover and housing and call this D 2. D1-D2
will be free axial movement of rotor. To position the rotor centrally between
the two cones with equal clearance on either side shims/spacer of thickness
equal to (D1+D2) ÷ 2 have to be introduced between the bearing cover and
housing and screws ‘B’ tightened firmly.

8.3. DISMANTLING THE PUMP:

If the axial movement is found to be excessive the pump should be dismantled

for inspection. Mark all the parts before dismantling to ensure proper re-
assembly. Also note down carefully the order in which each part is removed
from assembly. Disconnect the motor from the supply, remove ‘V’ belts,
disconnect the inlet and discharge manifold and seal water lines from the
pump and remove the pump and remove the pump from the skids. Lift the
pump from the skids and place it on two wooden blocks placed on level floor.

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 The body should rest on the blocks and the feet of the pump should be clear
from the floor. Remove the idle end outer bearing cover and shims/spacer.
Straighten lock washers. Remove lock nut and lock-washer. Remove nuts from
the studs, holding the head on the body fix a puller as shown in the sketch for
removing the idle end head from the body and the bearing form the shaft. Use
a protective pad between puller screw and shaft end to protect the shaft centre
form damage. Gradually tighten the screw to pull the head from the body and
the bearing from the shaft.

Remove driving end outer bearing cover. Remove lock nut and lock washer of
the bearing. Fix the puller as described earlier and push the rotor shaft
assembly towards idle end until the bearing seating on the shaft is free of
bearing. Remove the driving end head from the body and rotor and shaft
assembly from the housing.

REMOVING PULLEY

REMOVING BEARING

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 8.4.INSPECTION AND REPAIRS:

As the rotor does not rub against any stationary part there will not be any wear
but there will be loss of material due to corrosion and erosion after long use. If
the surfaces are uniformly eroded the running clearance will increase and can
be brought back within specified limits by adding packing/jointing between
cone and heads. If the erosion/corrosion is not uniform and is deeper at some
places the conical surfaces of cones and conical bores of rotor need machining
to clear the surface. The conical surfaces are at an angle of 8° from the axis of
rotor. Any reduction in the conical diameter of cones or increase in
corresponding bores of rotor will increase the free axial movement in the ratio
of 1:3.5. If the reduction of cones diameter is 1mm there is an increase of 3.5
mm in free axial movement. Extra packings should be added between cone
and head to compensate for this in addition to the packings that are already in
existence. Packings up to a maximum thickness of 6mm can be placed under
each cone. If cones need replacement compare the new cone with the old
cones for proper assembly. If rotor needs replacement use a press of suitable
capacity for removing the old rotor from the shaft and fixing the new rotor on
the shaft. Take care to see that the curved tips of rotor blades point towards the
direction of rotation.

8.5. REASSEMBLING:

For re-assembling introduce the rotor and shaft assembly without bearings in
the body. See that the curved tips of the rotor blades and the arrow marked on
the body point in the same direction. Place the gaskets on the head flange.
Bring the head and cone assembly nearer to the body flange. Before the end of
the shaft enters the bearing housing place the appropriate inner bearing cover
over the shaft and assemble the head to the body. Bearings can be introduced
with the help of a simple mounting tool as shown in the sketch. Lock the

20
 bearings on the shaft with nuts and washers. Measure the free axial movement
and find the thickness of shims/spacer required to position the rotor centrally
between the two cones as explained earlier. After all the parts are assembled
place the assembled pump on a flat machined surface and loosen all the nuts
on the studs holding heads and the body. This will allow the machined
surfaces on the feet of both the heads to assume the same place. If a level
surface is not available place the pump on the foundation skids and loosen the
nuts. After the feet touch uniformly the base check for any gap using a feeler
gauge and tighten all the nuts. When the feet are in alignment pack the stuffing
box and lubricate the bearings. Connect the pump to seal liquid/water supply
and suction and discharge piping. Mount the ‘V’ Belt pulley and the ‘V’ Belts.
Pump is ready for operation. See the instruction “operation” on sheet 4.

FIXING PULLEY

MOUNTING BEARING

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 9.1 STANDARD PARTS:
The following standard parts are fitted on the pump

QUANTITY DESCRIPTION LOCATION IN THE PUMP

2 Nos. Spherical roller Bearing Drive End and Idle End Head
21311 C
2 Nos. Lock Nut KM-11 -do-
2 Nos. Lock Nut MB-11 -do-
12 lengths Gland Packing ropes Stuffing Box
10mm Sq x 235 long
Graphited
20 Nos. M 12 x 60mm long studs Body to Head
20 Nos. M 12 Nuts -do-
16 Nos. M 10 x 25 Allen Screws S.S / Cone to Head
H.T
4 Nos. M 10 x 120 long stud I.E Bearing Housing
8 Nos. M 10 Nuts -do-
4 Nos. M 10 x 110mm long stud D.E Bearing Housing
8 Nos. M 10 Nuts -do-
5 Nos. M 10 x 35mm long Hex -do-
Screws
4 Nos. M 10 x 65mm long stud Gland – Head
4 Nos. M 10 Nuts -do-

9.2. RECOMMENDED SPARES:

Part No. Description Quantity

18 Bearing No. 21311 2 Nos.
12,15 Oil Seal 2 Nos.
21, 22 Packing 1 Set
9 Shaft Sleeve 2 Nos.
3,4,16,17 Rotor with shaft assembly 1 Set.
5 Set of cones 2 Nos.

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PARTS LIST

1 HEAD D.E / I.E 12 OIL SEAL – INNER COVER

2 BODY 13 BRG. COVER I.E. OUTER
3 ROTOR 14 BRG. COVER D.E
4 SHAFT 15 BEARING
5 CONE D.E / I.E 16 LOCK NUT
6 KEY (Discontinued) 17 LOCK WASHER
7 KEY – SHAFT / PULLEY 18 BEARINGS
8 GLAND 19 SHIMS / SPACER
9 SLEEVE – SHAFT 20 GLAND PACKING
10 BRG. COVER D.E INNER 21 PACKING CONE / HEAD
11 OIL SEAL-INNERCOVER 22 PACKING HEAD / BODY

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