Method Statement For Testing & Commissioning Of Vacuum System

Below is the list of equipment that you will need to perform the installation, testing & commissioning of Vacuum System.

• Tool box
• Hammer drill
• Grinder
• Level bar
• Hack saw
• Hammer
• Step Ladder / Scaffolding
• Pressure Gauges
• Pipe Cutter
• Flat / Round file
• Gas welding (Brazing) Set
• Nitrogen Purging Set
• Pipeline Pressure Testing Accessories
• Bending Tool
• Measuring tape
• Marker
• Drill machine
• Concrete bit
• Anchor punch
• Screw driver (flat & set)
• Fix spanner (4mm to 32 mm)
• Adjustable spanner
• Sprit level
• Safety requirements tools such as safety shoes, safety helmet, safety glasses, fluorescent vest, and safety gloves to ensure maximum ability of safe work and dust mask when required.
• Calibrated Pressure Gauges

Sequence Of Work

• The operator should carefully read the entire contents of manual before installing ,wiring , starting,operating , adjusting and maintaining the system.
• The operator is expected to use common-sense safety precautions , good workmanship practices and follow any   related local safety precautions .
• Before starting any installation or maintenance procedures ,disconnect all power to the package.
• All electrical procedures must be in compliance with all national,state and local codes and requirements.
• All wiring should be connected by a certified electrician.
• Refer to the electrical wiring diagram provided with the unit before starting any installation or maintenance work.
• Release all vacuum from the package before removing ,loosening, or servicing any covers,guards fittings ,connections or other devices.
• Notify appropriate hospital personnel if repairs or maintenance will affect available vacuum levels.
• This is a high speed rotating piece of machinery.Do not attempt to service any part while the machine is in operation
• To prevent automatic starting, disconnect all electrical power before performing any maintenance functions
• Do not operate unit without guards,shields or screens in place
• Make sure that all loose articles,packing materials and tools are clear of the package
• Check all safety devices periodically for proper operation
• Do not add lubricating oil of any kind to the vacuum pump. Absolutely no oil is required for proper operation
• Electrical service must be the same as specified on the control panel name plate or damage to the equipment may occur
• Vibration during shipment can loosen electrical terminals, fuse inserts and mechanical connections. Tighten as necessary.
• Ensure all concerned personnel shall use PPE (Personal Protective Equipment) and all other items as required.

COMMISSIONING PROCEDURE.

• Start Up Procedures
• Lubrication
  • Lubrication to be done by applying grease to the bearings with the grease supplied in the grease pack shipped with the pumps using the grease gun located on the pump.

Pump Rotation

• • The pumps must be checked for correct rotation prior to the actual operation.
  • Using the Hand-Off-Auto switch on the door of the control panel jog the motor of the specific pump that is to be checked by momentarily turning the switch to Hand and back to Off.
  • Observe the cooling fan on the side of the pump and determine the rotation of the pump and check whether its rotating clock wise.
  • If the pumps are rotating in the wrong direction, rotation can be reversed by switching any two main power leads at the bottom of the starter in the main control panel .Correct rotation should be confirmed in the previous manner.

General Operation.

 Electrical Control Panel.

• The Life Line multiplex control panel includes dual 120V control transformers with fuses and audible lag pump alarm, 0 -30″Hg vacuum gauge and the following for each pump hour meter, vacuum control switch, illuminated Hand-Off-Auto switch and motor starter with circuit breaker disconnect. Quadruplex systems have one main disconnect with one external operator. All components are enclosed in a NEMA 12 enclosure.
• During normal operations all H-O-A switches shall be turned to the ”Auto“ position so that the PLC can effectively control the system.
• The PLC monitors the system vacuum switch condition starts and stops the pumps depending on changing vacuum switch conditions and minimum run time values and automatically alternates the lead position between units.
• In a Quadruplex system PLC will signal the lead pump to start when the lead vacuum VS-1 closes with falling vacuum level. If the one pump can carry the load then the vacuum level will rise andVS-1 will open. At this point if the minimum run timer for that pump has been satisfied, the PLC will turn off the lead pump. If the minimum run timer for that pump has not been satisfied the lead pump will continue to run against the vacuum relief valve until the timer expires. When the system vacuum drops again and VS-1 closes, the PLC will automatically sequence the lead role to the other pump and will start it. If the lead pump runs continuously for more than 15 minutes the PLC will automatically sequence the pump attempting to evenly distribute the run time among all available pumps.
• If during operation, the second pump is required to come on in addition to the lead pump the PLC will turn on the “Lag Alarm”. To determine when the PLC turns on the lag alarm it counts the number of units in the “Auto” position and makes a decision based on the vacuum switch conditions.
• On the initial system start up when the system vacuum level is below the set points of the vacuum control switches all pumps will operate. During this initial system start-up the lag alarm will come on at this point and this is normal. It can be reset once the vacuum level is high enough to open the lag vacuum switch.

Relief Valve

• Vacuum pump is built with an integral vacuum relief to prevent the pump from operating at a vacuum level that is too high.
• The maximum operating point is factory set at 23 inches Hg.

Tank Drain

• The standard tank drain consists of a manually operated ball valve. To drain the liquid from the tank open the tank bypass valve and close the tank isolation valves.
• Then open the vent and drain valves.
• When draining is complete close the vent and drain valves first then open the tank isolation valves and close the tank bypass valve.

Emergency Shutdown/Alarms.

• Motor Overload Shutdown -This will shut down the pump in question and will not re-start until the reset button on the starter inside the main control cabinet is reset.
• Lag Unit Running Alarm– This alarm will activate if the last available vacuum pump comes on. If all four (4) H-O-A switches are set to “Auto” then the lag alarm will trigger when the fourth unit comes on. If on the same system three (3) of the four (4) H-O-A switches are set to “Auto” and the other to “Off” or “Hand” ,then the lag alarm will activate when the third unit comes on. To silence the alarm, press the amber push button .In the event the legal alarm is persistent to see if any leaks or valves are open downstream or reduce the system load. Please note that the lag alarm may be reset even if the lag pump is still running. This can happen due to the minimum run timer not having expired, but the lag vacuum switch itself may be open.

Vacuum Switch Set Point Adjustments

The vacuum switch is set at the factory to the operating point as given in the below table.

VACUUM SWITCH SETTINGS
VS-1	VS-2	VS-3	VS-4	RELEIF VALVE SETTINGS
19-21” hg	18-20” hg	17-19” hg	16-18” hg	23

 

• Cycle the switch to determine actual operating points before proceeding with readjustment.
• Adjust the range (Screw “A”) to required cut-in vacuum setting. Turning the screw clockwise lowers the cut-in and cut –out vacuum settings equally.
• Adjust the differential (Screw “B”) to the required cut-out vacuum setting .Turning the screw counter-clockwise will increase the cut-out vacuum setting only.