DESIG

GN MANU
UAL

SPD00
031ERN-U
USA
PR
ROCESS DESIGN
D M
MANUAL

VACUUM
M EQUIPM
MENT

R
REV. :2

DATE: 10 Jun 2011

2

HO
OLDS:
1. Section
n 2 – Form numbers
n to be
b identified

SAMSUN
S NG ENGIN
NEERING
G AMERIC
CA INC
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DATE: 10 Jun 2011
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CONTE
ENTS
1.  SCO
OPE ................................................................................................................................ 1 

2.  FOR
RMAT ............................................................................................................................. 1 

3.  SEL
LECTION GUIDE
G FOR
R VACUUM
M EQUIPME
ENT ............................................................. 1 

3.1.  Vacuum Equipment Selection

S Prrocedure ...................................................................... 2 
3.2.  Comparisoon of Opera ating Costs .................................................................................... 2 
3.3.  Properties of the Sucttion Gas ....................................................................................... 2 
3.4.  Type Selecction .............................................................................................................. 2 
4.  DET
TERMINAT GE ................................................................................ 2 
TION OF AIR LEAKAG

4.1.  General ......................................................................................................................... 3 

4.2.  Recommen nded Metho od for Air Leakage Esttimation ...................................................... 3 
5.  EST
TIMATION OF
O UTILITY
Y REQUIREMENTS ..................................................................... 4 

5.1.  Steam Con

nsumption ...................................................................................................... 4 
5.2.  Power Con
nsumption ...................................................................................................... 4 
6.  REF
FERENCES
S .................................................................................................................... 6 

7.  REV
VISION HIS
STORY........................................................................................................... 7 

8.  TAB
BLES AND FIGURES ..................................................................................................... 8 

Table 1 – Cost Study

S for Evvacuation Systems
S ........................................................................ 8 
Table 2 – Charac cteristics off Various Vacuum Pum mps ............................................................. 9 
e 1 – Selection Proced
Figure dure for Vaccuum Equip pment ....................................................... 10 0 
Figure
e 2 – Econoomic Comp parison of Steam
S Ejecttors and Va acuum Pum mps .......................... 11 1 
Figure
e 3 – Applic
cations of Vacuum
V Equ uipment ..................................................................... 12 2 
Figure
e 4 – Air Le
eakage Valu ues ............................................................................................. 133 
e 5 – Estimation Chartt of Ejector Steam....................................................................... 14
Figure 4 
Figure
e 6 – Typicaal P&ID for Steam Eje ectors ......................................................................... 15 5 
Figure
e 7 – Typicaal P&ID for Vacuum Pumps P ........................................................................ 166 
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1. SC
COPE
This ma
anual gives the guideliines for the
e selection of
o vacuum equipment,
e , the estima
ation
estim
mation of airr leakage, and
a a rough h estimation
n of utility consumptio
c n. P&IDs fo
or
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typiccal vacuum systems are

a shown in
n
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Fig
gure 6 and
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Fig
gure 7. It should be notted that com
mpleting a selection of vacuum equipment
e
sho
ould requiree pertinent informationn from the vendors.
v

A general
g clas
ssification of
o vacuum systems
s is as
a follows:

Vacuum
m Region Pressurre

Ro
ough 7
760 to 1 mmHg
m

Med
dium 1 to 10-3 mmHg
m

H
High 0-3 to 10-7 mmHg
10

Ultra
a-High 10-7 mmHg an
nd below

Thiis manual addresses

a s
systems forr rough and
d medium vacuum
v systems.

2. FO
ORMAT
e following forms1 sho
The ould be use
ed, unless otherwise
o specified:

- Ejecto
ors Form No.:
N
- Recip
procating pu
umps Foorm No.:
- Rotarry pumps Form No.:
- Fans & blowers Form No.:

Hold #1: Form

m numbers

3. SE
ELECTION
N GUIDE FOR VAC
CUUM EQ
QUIPMEN
NT
Vaccuum equip pment can beb roughly divided into o two typess, steam ejeectors and
vaccuum pump ps. The vaccuum pumps include: reciprocatin
r ng pumps, liquid-ring
seaaled (NASHH) pumps, rotary
r (oil se
ealed) pummps, and me echanical blowers (Ro oots).
Ste
eam ejectorrs usually have
h a lowe er capital co
ost, no movving parts, high
h reliability,
andd high steam consump ption. Vacuum pumps have a high maintena ance cost (55 to
20 times higheer cost than
n steam eje ectors), and
d low utility consumptioon.

3.1. Vacuum Equipmentt Selection Procedure

A flow ch
hart showing the selecction proced
dure for vaccuum equip
pment is

1
Form de
etails to be prrovided later.
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presente
ed in Figure
e 1.
3.2
2. Comparison of Ope
erating Costts

Criteria for
f selecting g steam ejeectors and vacuum
v pum
mps in term
ms of opera
ating
cost is prresented in Figure 2. As
A a genera al rule, whe
en the suctio
on gas volu
ume
is large and
a the ope erating presssure is high, vacuum pumps havve an opera ating
cost that is lower than steam ejectors.
e Steeam ejectors produce a large
quantity of waste liq
quid, which is a disadvvantage unless the cosst of the waaste
liquid treatment/dispposal is ine
expensive.
3.3
3. Propertie
es of the Su
uction Gas

When co orrosive gasses must be

e handled, steam ejecctors, which
h can be
manufacctured from almost anyy material, can
c be adva antageous.. An examp
ple is
the cost study for a vacuum fla
asher mentiioned in
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TABLES AND FIG

GURES
Table 1.
In te
erms of utility consumption,
c v
vacuum pumps s are typically more
m advantag
geous than ste eam ejectors. However,
H
becaause H2S is ty ypically present in the suction
n gas, the vacu uum pumps wiill require highe
er initial cost and
a may
posee problems witth reliability.
Vacu
uum pumps ha
ave an advanta
age in fouling services.
s
3.4. Type
e Selection

Once th
he operating prressure is know
wn, the numbe
er of steam eje
ector stages re
equired can be
e determined frrom
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Figure 3. In se
F electing the typ
pe of vacuum pump,
p the charracteristics of the
t available ty
ypes and the p process conditions
involved must be fully considdered. Contactt with vendors may be neces ssary. The characteristics of vacuum pump ps are
g
given in
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Table 2.
4. DE
ETERMINATION OF
O AIR LE
EAKAGE
It should
s be nooted that aiir inleakage
e is really a function off system ma aintenance e.
The e objective of the designer is to determine
d a reasonablly conserva ative basis forf
thee vacuum sy ystem desig gn. Traditio
onally, air inleakage haas been esttimated as a
funnction of sys
stem volum me, or as a function
f of the number of flangess and fittings.
The e system presented be elow is bassed on syste em volume. Also, the designer
d
sho ould note th
hat air inlea
akage is esttimated in units
u of masss (kg or lb)) per hr; the
e
leaakage rate in mass units is typicallly lower at lower vacu uum pressu ures, despite e
thee higher preessure differential.

4.1. General

For an es stimate of aira leakage into the vacuum systeem as a fun

nction of
system volume,
v it iss recommen
nded to usee Figure 4, and the curve labeled “30
Torr/h” irrrespective of operating
g pressure.
Systemss which have more leak locations than norma al or include agitators
(whose shafts
s are poorly
p seale
ed) should be
b given an
n additional allowance. For
p agitatorr.(4)
instance, 5 lbs/hr off air should be added per
2. Recomm
4.2 mended Metthod for Air Leakage Estimation
E
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Figure 4 is recommended by th he Heat Exxchange Insstitute and has

h been
conventioonally used ge.(4) When
d to estimatte air leakag n past leak test valuess are
plotted against the recommend
r ded values, it is found that the tesst values are
smaller than the reccommended d values. Concerning g the leak rate,
r some
clients ha
ave their ow
wn standard ds. For insttance, Commpany A ado opts 50 Torr/5
hours; Company B adopts 3 To orr/hr; and Company C, C 25.4 Torrr/hr. For theese
reasons, SECL reco ommends that the air leakage be e taken as 30
3 Torr/hr,
except as noted in Section
S 4.1 above.
A few additional nottes on the sizing
s basiss:
a) The air
a estimate e leakage given by the “30 torr/hr”” curve on Figure
F 4 is
signifficantly lesss than the trraditional estimates froom Heat Exxchanger
Institu
ute (HEI) Standards. ThisT can bee seen by co omparing thhe 30 torr/hhr
line to
o the other curves on Figure 4. It should be noted tha at the value
e
obtainned from th hose curvess was some etimes multtiplied by a factor of 1.5 or
2.0 to
o obtain a design
d valuee. As the acctual air lea
akage may be significa antly
largerr or smallerr depending g upon the conditions of sealing, maintenance
factorrs, and app plication, thee HEI estimmate could result
r in a system
s withha
capab bility far beyyond that reequired for a reasonab bly well ma
aintained
vacuu um system.. This syste em capabilitty could proovide a quicck recoveryy
from upsets due e to surges of process non-conde ensables, ettc. As pointted-
out in
n Note b of Section 5.2 2, evacuatio on time cann become ana issue for
more tightly designed syste ems with large quantities of non-ccondensable
gases s..
b) Vacuum System m sizing is based
b on sa
aturated vapor (including processs
non-ccondensables, cracked d gases, etc), not simpply the air in
nleakage.
Calcuulation musst be made to account for the flow w rate and composition
c n of
the vaapor and no on-condenssable gas entering
e the
e vacuum syystem, in
additiion to the estimated
e aiir leakage rate.
r
c) A des
sign margin ughput, nott the suction pressure.
n is applied to the throu
The pressure
p drrop from the
e vacuum vessel
v to the
e vacuum system
s musst be
prope
erly accounted for.
5. ES
STIMATIO
ON OF UT
TILITY RE
EQUIREMENTS
Utility consum
mption is dettermined byy the vendo
ors. Howevver, steam and
a power
nsumption may
con m be rou ughly estimaated as follo
ows:

5.1. Steam Consumptio

C n

Where th
he suction gas
g is rich in non-conddensable gaases, the stteam
consumpption may be
b estimated d from Figu
ure 5 by con
nverting the
e suction ga
as
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volume to its equivaalent air vollume. Wherre a large quantity

q of condensabl
c le
vapor is present in the
t suction gas, steam m consumpttion may be e estimated
d by
using esttimated preessures and d the suctio
on gas volum
me at the inndividual
stages off the ejecto
or.
5.2
2. Power Consumption
n

The BHP
P (kW) of all types of vacuum
v pum
mps may be d as followss (1):
e estimated
- NA
ASH pump (Size Factor valid bettween 0.05 and 35)
BH
HP = 10.3 × actor) 0.924
(Size Fa
a) Recip
procating pu
ump (Size Factor
F valid
d between 1.00
1 and 25
5)
actor) 0.963
HP = 5.33 × (Size Fa
BH
b) Rotarry piston pu
ump (Size Factor
F valid
d between 0.03
0 and 8)
actor) 1.088
HP = 5.69 × (Size Fa
BH

Where,
Siize Factor = Air Quanttity (lb/h) / Operating
O P
Pressure (To
Torr).
Notes
s:
a)) Where the evacuatioon time beccomes a bo ottle-neck in
n the design
n,
the evacu
uation time may be ma ade longer or start-up equipment
may be in
nstalled sep
parately to reduce
r utilitty consump
ption.
b)) When the e system haas a large quantity
q of non-conden
n nsable gase
es
that can produce
p a possible
p red
duction of operation
o a parallel
installatio
on of vacuum devices should be considered
c .
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6. RE
EFERENC
CES
i. George
e A Hutt, Jr., Chemical Engineering, March 15, 83 (197
76)
ii. "Vacuu
um Flasher Design Ma
anual"
iii. "Chemical Engine
eering Manu
ual", 3rd Ed
d., Chemica
al Engineering Institute
e of
Japan (1968)
iv. ard for Stea
"Standa am Jet Ejecctors", 3rd Ed.,
E Heat Exchange
E In
nstitute (195
56)
v. "Equipm
ment Desig
gn Handboo
ok", 2nd Ed
d., Gulf Pub
blishing Com
mpany (197
71)
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7. RE
EVISION HISTORY
H Y
SE
EA issue off SPD0031E
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REV NO. DAT

TE S
SCOPE DES
SCRIPTION
N

-Team: Process
P En
ngineering
evised for
Re
n
new Doc. -Prepared d by: K. Elliott
E
2 10 Jun 2011
Nuumbering -Checked by: S. Wenger
W
System
-Approved
d by: M. Czaikowsk
C i

eviously is
Pre ssued as SEM-9429E-USA

REV NO. DAT

TE SCOPE DES
SCRIPTION
N

First Editio
on – SEA
-Team: P
Process En
ngineering
1 30 Nov 2010 AL
LL PAGES -Prepared
d by: A. Co
oulam / P.N
N. Reddy
-Checked by: M. P. Czaikowski / H. Feintuch
-Approved
d by: T. Sutikno
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8.
8 TABLES
S AND FIGU
URES
Table 1 – Cost Stu
udy for Evacua
ation Systems
DESCRIPTION Casse 1 Case 2
CLIENT A B
VACUUM FLASHER
CAPACITY (BPSD)
SYSTEM OF VACUUM M COLUMN 65000 SEM
MI-DRY 50,000 WET
SUCTION CONDITIONN TEMP. 43.5 TEMP. 34.5
(STUDY BASIS) PRESS. 13
3mmHg-1000mmHg PRESS. 54mmmHg-935mmHg
FLOW 46.6 M3/S FLOW 7
7.85 M3/S
H2S 8.2 Kg-Mol/H H2S 6..3 Kg-Mol/H
C2 19.1 〃 C2 14.8 〃
H2O 83.2 〃 H2O 58.5 〃
13
3mmH 1000mmHg 1000mmHg 63mmH 5 TOTAL 935mmHg
935mmHg 63mmH 54mm
13.5℃
1 TOTAL13mmHg 60mm 110.5 〃 14.5
54m 79.6 〃
VC.PUMP VC.PUMP

SYNPLIFIED
FLOW OF
EVACUATION SYST..

EVACUATION SYST.. EJECTOR

R SYSTEM VACUUM PUM
MP SYSTEM EJECTOR SY
YSTEM VACUUM PUMP SY
YSTEM
MAIN EQUIPMENTS
SIZE & COST DESCRIPTION - ×10⁴YEN DESCRIPTION - ×10⁴YEN DESCRIPTION - ×10⁴YEN DE
ESCRIPTION - ×10⁴YEN
EJECTORS 4Series 920 EJECTORS 2S
Series 500 EJECTORS 2Se
eries 250 RO
OOT-NASH 2-3Serie
es
1st CONDENSER 770 M² 2000 1st CONDENSER 770 M² 2000 P
PRECONDENSER 24400 M² 6400 -KENEY 2300
2nd CONDENSER 150 M² 480 NASH Series
2S 30000 1 CONDENSER 360
1st 0 M² 940 PRE
ECONDENSER 2440 M
M² 6400
3rd CONDENSER 80 M² 340 ×3
3Para 2 CONDENSER 130
2nd 0 M² 450 - - -
TOTAL - 3740 TOTAL - 32500 TOTAL - 8040 TOTAL - 29400

UTILITY CONSUMP.
& COST DESCRIPTION - ×10⁴YEN DESCRIPTION - ×10⁴YEN DESCRIPTION - ×10⁴YEN DEESCRIPTION - ×10⁴YEN
15.5K STEAM 11.7T/H 35200 ELEC. for NASH 500
0-700Kw 7000-9800 H.P. STEAM 6.8T
T/H 21760 ELEC.for 500 - 7000 -
COOL WATER 750T/H 3300 15.5K STEAM 8.7T/H 27840 - - - VAC
CUUM PUMP 600Kww 8000
- - - COOL WATER 75
50T/H 3300 COOL WATER 24200T/H 10650 CO
OOL WATER 2420T/HH 10650
TOTAL - 38500 TOTAL - 38140 TOTAL - 32410 TOTAL - 17650 -
-40940 19050

NOTE 1) UTILITY COST HP STEAM 4000 YEN/TON 2 EQUIPMENT COST

2) T BASED ON THE FIRS
ST HALF OF 1975
(S51.2 BASED) ELECT. 17.5 YEN/KwH
COOL WATER 5.5 YEN/TON
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Table
T 2 – Ch
haracteristics of Variou
us Vacuum Pumps

Suitab
bility for Suctiion Gas
Operating
O
Type
e Pressure
P Notes
Low Boiling
g
(Torr) Steam Dust
Gas

RECIPRO
O- Resista
ant to Corrossive
5 - 760 gaases.
One sta
age + + q
10-1 - 760 Require
es large spa ace for
Two sta
age + r + in
nstallation.

NASH 50
5 - 760 + + + Suitablee for chemiccal
(Water Se
eal) prrocesses.
Consum mes more po ower.
Liquid-ssealed circuit is
neecessary.

Roots
- Large exxhaust volume
e.
One Sta
age 300
3 - 760 + + q
- Consumes more pow
wer.
Two Sta
age 100 - 760 + + q

Rotary 10-4 - 760 - - - - Low resistance to corrrosive

(Oil Seal) gases.

10-3 - 10 + q r Large exhaust

e volu
ume.
Mechaniccal Consum mes less powwer.
booster Auxiliarry pumps
neecessary.

* It is po
ossible to lo
ower the ope
erating presssure by ad
dopting hea
avy liquid se
ealing.
+ : Strong
q : Slightly stro
ong
r : Slightly weak
- : Weak
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Fig
gure 1 – Se
election Pro
ocedure forr Vacuum Equipment
E

Determination of operating pressuress and suction gas

g
volume (Refer to Sectioon 4)

Selection of eje
ectors or vacuum
m pumps
(Refer to
o
Figure 1 – Selection Proocedure for Vacuum Equipment

Ejector Selection
Vacu
uum Pump Selection

Type sele
ection
(Refer to Esttimation of the number of
stages (Refe er to

Utility estim
mation
(Refer to Se ection 5) Barom
metric or surfacce condenser

Utility estima
ation
(Refer to Secttion 5)
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F
Figure 2 – Economic
E C
Comparison
n of Steam Ejectors an
nd Vacuum
m Pumps
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Figure 3 – Applicatiions of Vacuum Equipment

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F
Figure 4 – Air
A Leakage
e Values
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Figure 5 – Estimatiion Chart off Ejector Stteam

Leak Air (kg/hr)
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Figure 6 – Typical P&ID for Steam

S Ejecttors

Pressure
e in a vacuu
um system using steam
m ejectors can be con
ntrolled:
(a) By
y introducin
ng air or ine
ert gas from
m outside,
(b) By
y spilling ba
ack the mottive steam, or
(c) By ondensable gases in th
y recycling the non-co he system
Method (b)( and (c) should
s be employed
e in
n such case es where non-
condensable gasess are definite ely presentt in the systtem and thee introductio
on
of air into
o the system
m is not dessirable or where
w the quantity of off-gas
o musst not
be increa ased.
In the ca
ase of Metho
od (b), if no
on-condenssable gasess are not prresent in the
e
system, the
t flow of steam spilleed back maay be reverrsed to the equipment.
e .
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Figure 7 – Typicall P&ID for Vacuum

V Pumps