INSTALLATION, OPERATION

&
MAINTENANCE SPECIFICATIONS

FOR

SAFEGUARD/SWACO

VACUUM EQUIPMENT

100 HP VACCUM POWER SKID

RIG VACCUM TANK (RVT)
DUAL HOPPERS
DUAL HOPPER PLATFORM

Swaco, A Division of M-I L.L.C.

A Smith/Schlumberger Company
5950 North Course Drive
Houston, Texas 77072

Tel: 281-988-1868
Fax: 281-988-1888

MANUAL PART #90-90-916 (REV. A)

 DISCLAIMER

Recommendations made by Swaco are advisory only. Swaco shall not be liable
under any guarantees or warranties, expressed or implied, in any manner or form,
AND ALL WARRANTIES, EXPRESSED OR IMPLIED, ARE HEREBY
SPECIFICALLY EXCLUDED, and Swaco shall not be liable for the failure to obtain
any particular results from the use of any recommendation made by it or from the
use of this material. In no event shall Swaco be liable for incidental or
consequential damages.
 SAFEGUARD/SWACO
VACUUM EQUIPMENT

TABLE OF CONTENTS

Chapter Page

1. General Description 3-7

Introduction 3
Description 3
Safety Symbols 4
Transportation and Storage 5
Specifications 5-7
2. Installation 8-9
Safety 8
Vacuum Unit 8
Piping & Hoses 8-9
Rig Tank 9
Dual Hopper 9
Dual Hopper Platform 9
3. Commissioning Procedures 9-10
Pre Checks 9
Piping 10
4. Operations 11-13
Startup Procedure 11
Stop Procedure 11
Temperature Gauge 11
Vacuum Gauge 12
Dual Hopper Timer 12-13
5. Maintenance 13-14
Belt Tension 13
Oil Level 13
Electric Motor 14
Filter Cleaning/Change 14
Dual Hopper 14
Rig Tank 14
6. Daily Checklist 15

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7. Weekly Checklist 15
8. Troubleshooting Tips 16-17
9. De-Commissioning Procedures 17
10. Marathon Drive Motor 19-27
11. Rotary Lobe Blower 29-36
12. Vacuum Power Skid Schematic 37
13. Dual Hopper Schematic 39
14. Belt Tensioning 41

2
1. GENERAL DESCRIPTION

INTRODUCTION

This manual contains installation, operation, and basic maintenance instructions for the
Safeguard/Swaco vacuum collection equipment.

A primary goal of the Safeguard/Swaco vacuum collection equipment is to provide our client with a
versatile cuttings collection system for zero or minimal discharge applications. Installation time can
be drastically reduced from other systems such as screw and belt conveyer and also installed with a
minimum amount of modifications to the structure. Because of the modular components, each part
can be placed on an offshore structure where it is not conflicting with other systems. The main
purpose of equipment placement is to minimize and reduce movement of the cuttings from the
shaker house, into the skips or CRI (Cuttings Re-injection).

DESCRIPTION
Vacuum Power Skid
The Safeguard/Swaco Vacuum System is a versatile cuttings recovery and disposal tool. The
vacuum unit uses air to transport solids or liquids; cuttings, or waste, from the collection point
(shaker trough, rig floor, pit/pump room) to a discharge point (re-injection unit, cutting boxes or
double hopper) using a closed system. Closed system means that the system cannot be open to the
environment, or vacuum is lost. The vacuum system is not like a pump, where the pump uses the
medium for movement, a vacuum uses air. When air is no longer available for the system, it slowly
stops moving the medium, and will overheat.

Rig Vacuum Tank

The Rig Vacuum Tank (RVT) can be used in a variety of configurations and for cuttings collection.
Cuttings can be transferred to sealed skips by way of a vacuum lid designed to fill the skip from the
rear forward, eliminating the need for shovelling. A hopper can be used for collection, then
transferred to a skip. The RVT, also known as a Drop Tank, can be used for the recovery of mud in
the event of a spill on the rig or cleaning the rig floor and pit room. If the spill is not contaminated
(check with Mud Engineer) the mud can be returned to the mud system via the shakers to remove
any solids.

Dual Hopper
The Dual Hopper consists of an Upper Hopper and Lower Hopper. The Upper Hopper is fitted with
two (2) vacuum line ports, one (1) 4 inch male and one (1) 6 inch male, cam lock coupler. Media
input to the Upper Hopper consists of one (1) 6 inch male, cam lock coupler. Both the Upper and
Lower Hoppers employ a 12 inch butterfly valve to transfer media from the Upper Hopper to Lower
Hopper and from the Lower Hopper to a discharge point. The butterfly discharge valves cycles are
timed from a control panel to suit the fill and discharge requirements. Air vibrators on both hoppers
insure continuous flow of media.

Dual Hopper Platform

3
The Dual Hopper Platform is used as a mounting for the Dual Hopper assembly. The platform is
equipped with access ladder, hand rails, and platform grating for maintenance. The platform also
houses the Dual Hopper control panel.
Safety and Information Warnings
Listed below are the graphic symbols and meanings used in this manual and are also located on the
Safeguard Vacuum System components.

Caution: risk of danger

Electrical Shock Hazard DO NOT OPEN

Caution HOT SURFACE

Hearing Protection Required

Read Instruction Manual

Lifting Points

Filter Clean/Change

Direction of rotation

DO NOT Operate with Guards removed.

4
Transportation/Lifting and Storage Requirements

Caution: Use certified lifting points indicated by

A. 100 Hp Vacuum Power Skid is provided with a certified lifting sling and forklift pockets for
moving the skid.
B. Rig Vacuum Tank is provided with two (2) lifting eyes and forklift pockets for moving the tank.
C. Dual Hopper Assembly is provided with four (4) lifting eyes on the upper hopper. The lifting
eyes are designed to lift both upper and lower hoppers when assembled together. The lower
hopper is provided with forklift pockets for moving either the single lower hopper or the upper
and lower hopper assembly.
D. Dual Hopper Platform is provided with four (4) lifting eyes at the top of the platform for moving
the platform. The lifting eyes have been designed to move the platform with the empty Dual
Hoppers mounted in their operating position.

IMPORTANT: A secondary set of four (4) lifting eyes are located on the side of the Platform.
These lifting points are only intended for moving the platform with the Hoppers
removed.
E. Storage limitations: Refer to motor and vacuum pump data for limitations.
Motor and vacuum pump should be run for 15 min.each week.

F. Storage conditions: - 20º C to + 40º C, corrosion protection recommended for motor and
blower, when stored for prolonged periods.

SPECIFICATIONS:
VACUUM SYSTEM
VACUUM POWER SKID
TECHNICAL SPECIFICATION
Noise Emission: A-Weighted Sound Power Level LwAd (ref. 1pW) 82 dB
A-Weighted Sound Pressure Level LpAd (ref. 20 uPa) 81 dB

The Safeguard/Swaco Vacuum System is a powerful drill cuttings collection system designed
specifically for offshore applications. Easy to install with little or no welding required, it minimises
costly rig time for preparation and installation. At the heart of the system is the Vacuum Power
Skid. Patented, the “Quiet Vac” Power Skid features: insulated noise depression enclosure,
explosion proof (Class 1, Zone 1) motor100hp, and gas detector.

Specifications:
Pump Inlet Port: 6 inch Cam Lock (behind control panel door)

5
Pump Exhaust Port: 8 inch with rain guard (on roof)
Operating Temperature Range: - 20º C to + 40ºC (ambient temperatures)
Mains Power Requirements: 380 volts / 50 Hz / 3 Phase
Control Panel Schematic: See Page 33.
Electric Valve Actuator: 4 inch valve actuator/110 volt (see control panel
schematic
Safety Devices:
Gas Detector: Sensor installed inside the filter container.
Low Alarm calibration at 20% LEL (Methane)
High Alarm/Shutdown calibration at 40% LEL (Methane)
Emergency Stop: Installed at Control Panel. Stops all operation upon activation.
Fixed Belt Guard: Installed around drive belt, motor sheave and blower sheave.

Model Length Width Height Weight

100 HP 134” 75” 103” 9,000 lbs.
3400mm 1900mm 2615mm 4080 kg

DUAL HOPPER
TECHNICAL SPECIFICATIONS

Hearing Protection Required.

Noise Emission: A-Weighted Sound Power Level LwAd (ref. 1pW 95 dB
A-Weighted Sound Pressure Level LpAd (ref. 20 uPa) 93 dB

Continuous feed hopper used in the collection of Oil Based Mud cuttings and other liquids and
solids. Used to funnel cuttings into conventional skips. Electrically timed actuators control cuttings
flow to match the rig’s drilling rate. Lower hopper is equipped with a swivel chute to allow 2 skip
to be placed side by side. When one skip is filled it can be moved out of the way, the chute can be
positioned to the other skip until an empty skip can be positioned.

Specifications:
Upper Hopper Cutting Inlet Port:
Upper Hopper Vacuum Ports:
Upper Hopper Discharge Port:
Lower Hopper Vacuum Brake:
Lower Hopper Outlet Port:
Operating Temperature Range:
Mains Power Requirements:
Control Panel Schematic:
Operating Air Pressure:
Hopper Vibrators:
Butterfly Valves:
(1) - 6 inch Cam lock
(1) - 6 inch and (1) 4 inch Cam lock
(1) - 12 inch air activated butterfly valve
(1) - 3 inch air activated butterfly valve
(1) - 12 inch air activated butterfly valve
- 20º C to +50º C (ambient temperatures)
110 volts ∪AC / Single Phase / 50 Hz
(Supplied from Vacuum Power Skid)
See Page 34.
80 psi
80 psi

6
Safety Devices:
Current limiting fuses Current limiting fuses on mains input and butterfly valve
solenoids.

Model Length Width Height Weight

Dual Hopper 63” 63.” 117” 4,200 lbs.
1,600mm 1,600mm 2,960mm 1,876 Kg
Each hopper (2) Capacity = 5 bbl each
RIG VACUUM TANK (DROP TANK)
TECHNICAL SPECIFICATION
As its name implies, the RVT functions as the rig’s central vacuum cleaner canister. By collecting
into the RVT, liquids can be returned to the mud system via a 2” diaphragm pump. 2” hoses will be
used to clean up spills on the rig floor and around the deck. Always use the RVT within the system
to stop any solids from entering the vacuum filter.

Specifications:
Inlet Port:
Outlet Port:
Secondary Vacuum Port:
Tank Drain Port (gravity):
Tank Drain Port (pumped):
Operating Temperature Range:
Operating Air Pressure:
(1) - 6 inch and (1) - 4 inch Cam lock
(1) - 6 inch and (1) - 4 inch Cam lock
(1) - 2 inch Cam lock
(1) - 2 inch Cam lock
(1) - 2 inch Cam lock
- 20º C to + 50º C (ambient temperatures)
80 psi

Safety Device:
Fluid level switch: Safety switch located on the side of the Rig Vacuum Tank
limits fluid level in the tank. When fluid level switch is
activated this switch will shut down the Vacuum Power
Skid.

Model Length Width Height Weight

RVT Tank 62” 51” 74” 2,700 lbs.
1574mm 1279mm 1880mm 1,200 Kg

DUAL HOPPER PLATFORM

TECHNICAL SPECIFICATIONS
The Dual Hopper Platform is designed to house a Dual Hopper assembly. The platform allows the
Dual Hopper to be elevated above the work area to facilitate the discharge of media into appropriate
vessels. The Dual Hopper electrical control system is also located within the platform. Access
ladder, maintenance landings, and handrails with toe plates are also provided.

7
Specifications:
Mains Input Power: ~110Vac / 50 Hz, Single phase for Dual Hopper (supplied from
100 Hp Vacuum System control panel).
Safety Device:
Guard rails: Upper level of platform is equipped with handrail, knee rail, and
toe plate.

Model Length Width Height Weight

Dual Hopper 96” 95.7” 202.0” 4,546 lbs.
Platform
2438mm 2432mm 5131mm 2,029 kg

2. Installation

Safety

USE LOCK OUT/TAG OUT FOR ALL ELECTRICAL CONNECTIONS AND

MAINTANCE PROCEDURES. Never operate the system with any electrical panels OPEN and
power connected.

ALL ELECTRICAL INSTALLATIONS AND CONNECTIONS MUST BE

SUITABEL FOR ZONE 1 APPLICATIONS.

ONLY A QUALIFIED ELECTRICIAN CAN CONNECT ELECTRICAL POWER

TO VACUUM SYSTEM. Insure the earth cable is properly connected and all connections tested
prior to operation.

NEVER OPERATE THE VACUUM WITHOUT AIR ACCESS WHEN STARTING.

The dust cap or the manual air valve must be open to allow air into the vacuum unit when starting
the unit. If no air is allowed into the vacuum system, it will place the motor and the blower under
stress and could cause damage to the system.

USE ALL SAFETY DEVICES INCLUDED WITHIN THE SYSTEMS.

The level switch (level indicator) must be in place and connected to the vacuum unit via 2.5-mil
wire prior to operation.

VACUUM POWER SKID UNIT:

1. Insure the Power Vacuum Skid is placed on a level surface, or the blower will not have
proper lubrication.
2. Insure access doors are not blocked.

8
3. Insure position of hoses entering the inlet will not block walkways.
4. Connect 4” or 6” hose from vacuum air inlet (Male camlock), to the RVT with either the 4” or 6”
female camlock located on the top of the RVT. Just below the camlock fitting, is a baffle to
prevent solids from by passing the RVT and entering the vacuum unit.
5. Insure the hose is not kinked, as this will restrict the flow of air from the RVT to the vacuum
unit.
6. If the hose exits the connection and is placed on the deck, it is recommended to use one or two
90-degree sections to prevent kinks in the hose.
7. Insure Main System Ground is secured to the “PE” (Protective Earth) terminal.

PIPING & HOSES:

1. It is more favorable to reduce distances for cuttings to be transported, than air lines. When at
all possible, reduce distance for cuttings to move from trough to skips, CRI unit or hoppers.
2. If 2 or more lines are fed from the same CRI unit or hopper, close attention must be kept on the
amount of air entering from the line with the least resistance. Valves can be incorporated into
the system to reduce the flow from one suction line.

RIG VACUUM TANK:

1. Mount Rig Vacuum Tank on a level surface.

2. Install Level Switch wiring at the normally closed, common and ground terminals provided.
3. Install 4mm² Green/Yellow external ground bonding wire from ground terminal of Level Switch
to bonding terminal of Rig Vacuum Tank.
4. Insure Main System Ground is secured to the “PE” (Protective Earth) terminal.
5. Level Switch wiring is to be installed to meet ZONE 1 applications.
6. Install air line to air operated diaphragm pump. Air line pressure not to exceed 120 psi.

DUAL HOPPER:

1. Mount Dual Hopper assembly using lifting eyes on Upper Hopper unit.
2. Secure Dual Hopper assembly to Dual Hopper Platform using, 8 each, 5/8 X 2 inch ( M16 X
50mm) low alloy steel bolts and nuts.
3. Install power cables from the Dual Hopper Platform to each of the three solenoid/valves
assemblies. Flameproof M20 glands are provided.
4. Power and bonding connections for solenoid/valve assemblies are to be installed for ZONE I
applications and routed in cable trays provided on the Dual Hopper assembly.
5. Install air lines for butterfly valves and vibrators. Air lines to be routed in cable trays provided.

DUAL HOPPER PLATFORM:

1. Mount Dual Hopper Platform on a stable, level surface.

2. Secure handrails to the top of platform with hardware provided.
3. Install floor grating on platform.
4. Mount Dual Hopper Assembly per instructions above.

9
5. Power and bonding connections for Dual Hopper control panel are to be installed for
ZONE I applications and routed in cable trays provided on the Dual Hopper Platform.

3. Commissioning Procedures

Vacuum Power Skid

Pre-Operational Checks:

Read Instruction Manual

a. Check oil level in Roots Rotary Lobe Blower. (both lobes) 64 Fl. Oz (1.89 Liters)
at gearbox side and 32 Fl. Oz (0.95 Liters) at drive side. The blower is shipped
with ISO-VG 320 industrial non detergent oil installed.
See Roots RCS-J instructions manual for details regarding service, allowable
fluids, operation and maintanince requirements.
b. Insure proper belt tension, see Maintenance section of operating instructions.
c. Insure all guards are in place and secured.
d. Inspect Ground Buss Bar at Main Control Panel for loose ground screws, which may
have been loosened in shipment.
e. Check external main ground system to Protective Earth terminal on the Vacuum
Power Skid, Rig Vacuum Tank, and Dual Hopper Platform (if used). Protective
Earth point is marked with “PE” symbol at the base of each unit.
f. Insure all ground connections are secure and free of paint or grease.
g. Insure all connections in control box and mains input box are tight and secure.
h. Install electrical mains input to junction box.
i. Insure no foreign objects can inter inlet port.

Electrical Requirements: Mains Input, 380 volts / 3 Phase / 50Hz

Full load current: 140 amps. (at maximum vacuum)

Caution: Shock Hazard

Qualified Electrician required to connect power to Vacuum Power Skid, Rig Tank
and Dual Hopper.
Appropriate lockout/tagout procedures are to be followed.
Wiring and grounding must comply with EN Standards for Zone 1 applications
and applicable Electrical Codes.

Piping

Caution: Danger of drawing in. Keep clear of open vacuum lines. Insure all inlets
have filter covers installed and loose gear is clear from area.
10
Principle: All piping, vacuum hoses and equipment will need to be checked for sealing prior to
commissioning. If a full vacuum cannot be generated in the piping system, it will not operate
properly. Therefore all piping, hoses and equipment needs to be checked one section at a time
starting with the vacuum unit. The following procedure takes into account all piping and hoses
have been measured, and connected in place.

1. Disconnect hoses from RVT, CRI, and disconnect bazooka.

2. Turn vacuum unit on, but leave air inlet valve open.
3. Blank off air inlet on RVT, and slowly close air inlet valve on vacuum. The vacuum gauge
should rise slowly up approaching 27” (-. 9 bar). If not, check hose connections and RVT for
seals. Release vacuum in system by the air inlet valve before repairing, correcting problem or
moving to next step.
4. Connect hoses to CRI unit, and blank off air inlet on CRI unit. Slowly close air inlet valve on
vacuum unit. Vacuum gauge will take longer to approach 27” (-.9 bar) because of the additional
air which needs to be removed from CRI unit. Check all connections for airtight fits. Release
vacuum in system by the air inlet valve before repairing, correcting problems.
6. Connect hoses to bazooka and blank off bazooka. Slowly close air inlet valve on vacuum unit
and check connections as before. Release vacuum in system by the air inlet valve before
repairing, correcting problems or turning unit off.

4. OPERATIONS
Startup Procedure
a. Follow appropriate LOCK OUT / TAG OUT PROCEDURES.
b. Open air valve behind access door; insure no foreign objects can enter inlet port.
c. Check rotational direction of blower by jogging motor to inspect direction. Jog
motor by pushing Start button to start and Emergency Stop to stop unit.
Correct direction if necessary. (Counter clockwise viewed from sheave side.)
d. Insure Filter valve is closed.
e. Install (if required), Remote Stop / Start, and Remote Emergency Stop.
Refer to Vacuum Power Skid schematic for wiring. Wiring must meet ZONE 1
applications.
f. Insure EMERGENCY STOP BUTTON is pulled in the OUT position
g. Turn mains power switch to ON position, (lever switch).
h. Press START button. If unit does not start, push the Gas Reset/Stop button. Press
START button again.
i. When unit reaches full power, close air valve inlet port to create a vacuum in piping.
NOTE: The electric valve actuator will take 60 seconds to completely close.
Vacuum will increase as valve is closing.
j. Check vacuum gauge for 8 in. Hg. – 12 in. Hg. / .2 - .4 bar (Normal reading).
Allow unit to run for 2 minutes. Check for any abnormal vibration, fluid leaks,
vacuum leaks, or abnormal noise.

Stop Procedures:

11
1. Open air valve behind vacuum access door.
2. The vacuum system has a 4-inch electric actuated valve to release vacuum prior to shutdown,;
the vacuum unit will not turn off immediately. Then the “System Stop & Gas Reset Pushbutton” is
pressed, the electric valve inside the vacuum unit will open to release the vacuum. It will take about
30 seconds; then the motor will stop. The electric actuator will allow vacuum to decrease below
10” Hg (-.3 bar) prior to shutdown. Any backspin on the 100 Hp vacuum units can cause serious
damage to the system.
3. Open air valve located behind access door of control compartment.

Ranges:
Temperature gauge reading:

100°F – 275°F(40°C-135°C): Normal temperature gauge reading.

300°F (150°C): Overheating; partially open air valve until temperature begins to
decrease. Allow unit to slowly cool.

350°F (162°C) Caution: Do not turn off unit, open air valve to allow vacuum unit to
cool.

Vacuum gauge reading:

8”-12” (.2 -. 4 bar) Normal

12”-20” (.4 -. 7 bar) Operating with collections
20”-27” (.7 -. 9 bar) Watch unit carefully, air may be needed to cool off unit if
operated for long periods in this range.

Dual Hopper

Electrical Requirements: Mains Input, 110 volts / Single Phase / 50Hz, supplied
from Vacuum Power Skid.

Caution: Shock Hazard

Qualified Electrician required to connect power to unit.
Appropriate lockout/tagout procedures are to be followed.
Wiring and grounding must comply with EN Standards for Zone 1 applications
and applicable Electrical Codes.

12
(Timed Mode)

Timer T1 is for the top valve A

Timer T2 is for the bottom valve B

When looking in the electrical pane from the front, timer T1 is on the left-hand side.

It is recommended that the switch on both T1 and T2 timer are set in the one minute position and
then controlled via the percentage dial to give operational times between 60 seconds and 12
seconds. 60 seconds being when the dial is turned fully round to the 1 position, and 12 seconds
being when the dial is set at the 0.2 position.
The hoppers will leave the workshop with the timers set in the one-minute position.

The philosophy behind setting the timers is as follows:

1. Timer T2 set on one minute with the percentage dial at 0.4. This results in valve B being
open for 24 seconds and valve A closed for 24 seconds.
2. Timer T1 set on one minute with the percentage dial set at 0.6. This results in valve A being
open for 36 seconds and valve B closed for 36 seconds.

Before valve A opens, valve B closes to allow for continuous vacuum. Once valve A opens the 24
seconds of cuttings are being gathered in the bottom hopper which gives a total of 60 seconds worth
of cuttings in the bottom hopper before valve A closes and valve B opens, which starts the cycle
over again.

Only the one minute setting should be used to avoid blocking of the bottom hopper unless very slow
ROP (Rate Of Penetration) are experienced and then the ten minutes setting should be used and
adjusted between two and ten minutes with the percentage dial.

(Manual Mode)

In the manual mode the timing sequence of valve A and valve B is bypassed. In manual mode both
the B valves remain open for discharging media, valve A remains shut during manual operations.
THESE TIMER SETTINGS ARE DICTATED BY DRILLING CONDITIONS
BUT IT IS RECOMMENDED THAT THEY NEVER BE EXCEEDED
UNLESS VERY SLOW ROP’S ARE EXPERIENCED.

5. MAINTANENCE
Vacuum Power Skid
Belt tension

1. Check tension as per diagram on page 35.

2. To increase tension:
a. Back off motor tensioning nuts on front of electric motor.
b. Insure sheaves remain parallel by tightening both adjustment bolts the same amount.

13
3. When proper tension is measured, retighten lock nuts.

100 Hp (14M-3500-37) Polychain

Center Distance = 51 Inches (1.3 Meters)
New Belt Tension = 51.7 lbs. (227.5 Newtons)
Used Belt Tension = 45.1 lbs. (198.4 Newtons)

Oil Level / Oil Change

Caution: Turn off power (Lockout/Tagout)

Caution: Hot Surface and/or Hot Fluids, allow unit to cool before
checking or changing oil.
Oil Level Check:
1. Inspect sight glass, oil level gauge located on the lower half of each blower lobe.
Note: There are 2 gauges for the blower, one on each side. Both need to be checked.
2. If oil level is low, add oil to fill each sight glass.
3. Add recommended oil by removing oil fill breather at the top of each lobe.
4. Replace oil fill breather. Do not over tighten breather.

Oil Change:
1. Change oil at manufacturers recommended intervals. See Blower Data pages 26-32.
2. Remove oil fill breather.
3. Remove drain plugs (both sides) located below the sight glass and drain used oil in appropriate
container for disposal per approved methods.
4. Reinstall drain plugs.
5. Install new oil, per manufactures filling recommendations.
6. Clean up any oil spills from skid floor for disposal per approved methods.
Electric Motor Maintenance
1. Will be performed by shop personnel when returned after job. If Vacuum unit will remain on
job for extended periods of time, consult with shop personnel for lubrication.

Filter Cleaning

Clean or change filter at recommended intervals.

1. Remove crash panel and access panel from side of vacuum unit.
2. Crash panel may be removed for regular access to filter. NOTE: Pinned access bars to replace
the crash panel are located inside the Control Panel door.
3. Remove 4 bolts from round filter cover plate.
4. Remove cover plate noting the placement of the filter on the brackets.
14
5. Remove filter from brackets.
6. Preferred cleaning technique: Clean filter by using high-pressure washer & steam if available.
If filter is very dirty, use soap & hot water to remove contaminates. Clean by applying pressure
washer to inside of filter, cleaning outward through filter.
7. Allow filter to dry prior to replacing.
8. Spray a light coat of oil to filter. A light lubricant is preferred.

IMPORTANT: Insure all vacuum inlets and filter canister is free of loose debris.

8. Replace filter, insuring filter is supported on brackets. Replace plate and screw with
wing nuts.
9. Replace cover plate.
10.Run unit for 5 minutes to allow proper drying and lubrication.

Dual Hopper
1. Insure Dual Hopper air lines are equipped with an air dryer, lubrication and regulator devices.
2. Insure air dryer does not fill up with water. Release plunger on bottom of reservoir to allow
water to drain out of dryer.
3. Insure lubricator fluid (Kill frost) is topped off.
4. Insure cuttings are not sticking to inside of hopper. Clean out as needed.

Rig Vacuum Tank (RVT):

1. Check RVT at least daily to insure the proper operation of the system. If carry over is
excessive, check the skips more often. If using a hopper, set the timers to dump more often.
2. Check operation of 2” diaphragm pump. Lubricate O rings by using light oil in air line.

6. Daily Checklist
Piping System:

1. Check all sections of hoses for wear & tear. Especially on any sections that bend: sweeps,
45-degree and 90-degree bends. This is the first place to experience any wear and will be
the first sections, which will need replacing.
2. Make up sections of hoses, which will need replacing prior to them wearing out.
3. Use waste base oil to vacuum through the system by dumping slowly into the trough or ditch to
keep lines clean and clog free. This step will allow the system to operate more efficiently,
especially when using a hopper.
4. When using the vacuum system for centrifuge collection, the piping will need to be checked
more often. Sticky materials will cling to the sides of piping and reduce the diameter of
pipes quickly.

15
5. Monitor all skips to insure there is enough on board for the hole section (if skip & ship). If
there are not enough, inform the company representative & mud engineer.

Vacuum Unit:

1. Monitor vacuum & temperature gauge to insure proper operation of unit.

2. Check deck on inside of unit for oil leaks.

Rig Vacuum Tank (RVT):

1. Check RVT at least daily to insure the proper operation of the system. If carry over is
excessive, check the skips more often. If using a hopper, set the timers to dump more often.
2. Keep the work area clean and free of trip hazards.

Dual Hopper:

1. Insure air dryer does not fill up with water. Release plunger on bottom of reservoir to allow
water to drain out of dryer.
2. Insure lubricator fluid (Kill frost) is topped off.
3. Insure cuttings are not sticking to inside of hopper. Clean out when needed.

7. Weekly Checklist
Vacuum Power Skid:

Insure power is disconnected for checks:

1. Clean air filter.

2. Check oil level. Insure the pan of the vacuum unit is free of leaks.
3. Check belt tension.

IMPORTANT: If Vacuum Power Skid is left unused for more than 1 week, run system for 30
minutes with no load before putting back into service.

Rig Vacuum Tank (RVT):

1. Check diaphragm pump for proper operations.

2. Lubricate pump.
3. Check all seals for wear.

Hoppers:

1. Check timers for proper operation.

2. Clean inside of hopper thoroughly.
16
8. Troubleshooting Tips
Vacuum Unit

No Power:
1. Insure “Emergency Stop” button pulled out.
2. Insure main power switch is “on”.
3. Press “System Stop & Gas Reset Pushbutton”.
4. Inform Rig Electrician:
a. Insure main breaker is “on” (Rig power).
b. Have Electrician check breaker on inside of vacuum unit (100 Hp) (Bottom
left of panel).
Loss of vacuum:

If Skips & Hopper:

1. Check if full. Replace skip.

2. Check lid for proper seal.
3. Check 90-degree connections on top of skip.
4. Check hoses for breaks.
5. Check skip for any seals that leak.
6. Check hoses or pipes for clogs.
a. Disconnect all sections of pipe & hoses. Begin connecting pipe & hoses from the
RVT towards the collection point. When the section of pipe or hose has been
identified, place hose male to male. This will reverse the cuttings & clog to
release any caught pieces.
b. If the above step does not work to remove clog, hang the hose or pipe above a
skip, gravity will sometimes do the job.
c. If all above steps fail cut clog out of pipe.

If hopper:

1. Check if full
2. Open access hatch at top of hopper & clean out manually. Use water to assist
cuttings & mud out of hopper.
3. Insure timer is set for desired opening interval. If the hopper is clogging up from over filling,
check for the cause of the problem. If the material is very sticky, add base oil or increase
interval times.
4. Check all hoses for breaks or cuts.
5. Checks to insure all timers are operating.

If RVT:

1. Check lid for proper seal.

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2. Check valve on bottom of RVT is closed. Some air will escape through valve on diaphragm
pump if not properly closed.

If CRI:

1. Check pipes & hoses for leaks.

2. Check valves on CRI for leaks.
3. Check to insure CRI course tank is not full.

9. De-Commissioning Procedures

Caution: Shock Hazard. Turn off mains power feeding Vacuum Power Skid.
Qualified Electrician required to disconnect power to Vacuum Power Skid, Rig
Tank and Dual Hopper.
Appropriate lockout/tagout procedures are to be followed.

Caution: Use certified lifting points indicated by

1. Contact company representative for plans of personnel & equipment.
2. Contact administrative office personnel to inform of plans.
3. Conduct a full inventory of all equipment to be returned. Inform company representative of
any equipment damages or shortages.
4. All hoses that can be disposed of on the rig do so. Clean all hoses prior to disposal.
5. Clean all equipment prior to moving off location.
6. Inform office personnel prior to leaving the location.

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10.

Marathon

Motor Data

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11.

ROOTS

Rotary Lobe Blower Data

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37
OPERATION
Before operating a blower under power for the first time, recheck the unit and the installation
thoroughly to reduce the likelihood of avoidable troubles. Use the following procedure list as a
guide, but consider any other special conditions in the installation.

1. Be certain that no bolts, tools, rags or dirt have been left in the blower air chamber.

2. Be certain that inlet piping is free of any debris. If an outdoor intake without filter is used,
be sure the opening is located so it cannot pick up dirt and is protected by a strong screen or
grille. Use of the temporary protective screen at the blower as described under
INSTALLATION is strongly recommended.

3. Recheck blower leveling, drive alignment and tightness of all mounting bolts if installation
is not recent. If belt drive is used, adjust belt tension correctly.

4. Turn drive shaft by hand to make sure impellers still rotate without bumping or rubbing at
any point.

5. Make sure oil levels in the main oil sumps are correct.

6. Check lubrication of driver. If it is an electric motor, be sure that power is available and that
electrical overload devices are installed and workable.

7. Open the manual unloading valve in the discharge air line. If a valve is in the inlet piping,
be sure it is open.

8. Bump blower a few revolutions with drives to check that direction of rotation agrees with
arrow near blower shaft, and that both units coast freely to a stop.

After the preceding points are cleared, blower is ready for trial operation under “no-
load” conditions as set up under Item 7. The following procedure is suggested to cover this
initial operation test period.

a. Start blower, let it accelerate to full speed, then shut off. Listen for knocking sounds, both
with power on and as speed slows down.

b. Repeat above, but let blower run 2 or 3 minutes. Check for noises, and vibrations of .005 in.
(.13 mm) or greater.

c. Operate blower for about 10 minutes unloaded. Check oil levels. Feel cylinder and
heatplate surfaces for development of spots too hot to touch, indicating impeller rubs. Be
aware of any noticeable increase in vibration.

Assuming that all trials have been satisfactory, or that necessary corrections have been
made, the blower should now have a final check run of at least one hour under normal operating
conditions. After blower is restarted, gradually close the discharge unloading valve to apply

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working pressure. At this point it is recommended that a good pressure gauge or manometer be
connected into the discharge line if not already provided, and that thermometers be in both inlet and
discharge lines. Readings from these instruments will show whether pressure or temperature ratings
of the blower are being exceeded.

During the final run, check operating conditions frequently and observe the oil levels at
reasonable intervals. If excessive noise or local heating develops, shut down immediately and
determine cause. If either pressure rise or temperature rise across the blower exceeds the limit
specified in this manual, shut down and investigate conditions in the piping system or in the process
to which air is being supplied. Refer to the TROUBLE SHOOTING CHECKLIST for suggestions
on various problems that may appear.

The blower should now be ready for continuous duty operation at full load. During the first
few days, make periodic checks to determine whether all conditions remain steady, or at least
acceptable. This may be particularly important if the blower is supplying air to a process system
where conditions can vary. At the first opportunity, stop the blower and clean the temporary inlet
protective screen. If no appreciable amount of debris has collected, the screen may be removed.
See comments under INSTALLATION. At this same time, verify leveling, coupling alignment or
belt tension, and mounting bolt tightness.

Should operating experience prove that blower capacity is a little too high for the actual air
requirements, a small excess may be blown off continuously through the manual unloading or vent
valve. Never rely on the pressure relief valve as an automatic vent. Such use may cause the
discharge pressure to become excessive, and can also result in failure of the valve itself. If blower
capacity appears to be too low, refer to the TROUBLE SHOOTING CHECKLIST first. If no help
is found there, it may be possible to increase the blower speed. Before attempting this change,
contact the nearest Sales Office for recommendations. Be prepared to furnish data on actual air
requirements and operating pressure/temperature conditions.

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 LUBRICATION
A very simple lubrication system is employed in RCS-J Whispair blowers. All friction parts
– gears, bearings and oil seals – are lubricated by the action oil slingers which dip into the mail oil
sumps causing oil to splash directly on gears and bearings and also to fill the small reservoirs above
the bearings. From these oil flows, by gravity, through the bearings and to the oil seals. A drain
port is provided below each bearing to prevent an excessive amount of oil in the bearings. Entrance
of lubricating oil into the blower air chamber is prevented by the use of double shaft sealing. Lip
type seals, located inboard of the bearings in each headplate, effectively retain oil within the sumps.
Any small leakage that may occur, should the seals wear, passes into a cavity in each headplate that

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is vented and drained downward. In addition, sealing rings are provided on both shafts where they
pass through the inner walls of the headplates. These serve to reduce air leakage from or into the air
chamber and also minimize oil carryover into the air chamber. They are sufficiently effective to
enable the blower to handle gases, however.

Initial filling of the sumps should be accomplished with the blower not operating, in order to
obtain the correct oil level. Approximate oil quantities required for blowers of the various
configurations are listed in Table 3. Use a good grade of industrial type non-detergent, rust
inhibiting, anti-foaming oil and of correct viscosity per Table 2. For heavy duty service, a synthetic
lubricant, such as Roots Synfilm GT synthetic oil (Roots P/N 813-106-) is highly recommended.
This synthetic oil has a life expectancy of 4 times that of petroleum based oils.

The level should never be allowed to fall below the middle of the oil level gauge when the
blower is operating. It may rise on the gauge during operation, to an extent depending somewhat on
oil temperature and blower speed, but it should not be permitted to rise above the top of the oil level
gauge.

During the first week of operation, check the oil levels in the oil sumps about once a day,
and watch for leaks. Replenish as necessary. Thereafter, an occasional check should be sufficient.
It is recommended that the oil be changed after initial 100 hours of operation. Frequent oil
changing is not required unless the blower is operated in a very dusty location. Normal life
expectancy of petroleum based oils is about 2000 hour with an oil temperature of about 200°F. As
the oil temperature increases by increments of 15-18°F, the life is reduced by half. Example: Oil
temperatures of 230-236°F will produce life expectancy of 1/4, or 500 hours. Therefore, it is
considered normal to have oil change periods of 500 hours with petroleum based oils. In draining
the sumps, remove plugs (22) at the bottom.

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 SAFETY PRECAUTIONS

For equipment covered specifically or indirectly in this instruction book, it is important

that all personnel observe safety precautions to minimize the chances of injury. Among many
considerations, the following should particularly be noted:

§ Blower casing and associated piping or accessories may become hot enough to cause major
skin burns on contact.
§ Internal and external rotating parts of the blower and driving equipment can produce
serious physical injuries. Do not reach into any opening in the blower while it is operating,
or while subject to accidental starting. Cover external moving parts with adequate
guards.
§ Disconnect power before doing any work, and avoid by-passing or rendering inoperative
any safety or protective devices.

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§ If blower is operated with piping disconnected, place a strong coarse screen over the inlet
and avoid standing in the discharge air stream.
§ Stay clear of open inlet piping (suction area) of pressure blowers, and the open discharge
blast from vacuum blowers.
§ Stay clear of the blast from pressure relief valves and the suction area of vacuum relief
valves.
§ Avoid extended exposure in close proximity to machinery, which exceeds safe noise levels.
§ Use proper care and good procedures in handling, lifting, installing, operating and
maintaining the equipment.
§ Casing pressure must not exceed 25 PSI (172 kPa) gauge. Do not pressurize vented
cavities from an external source, nor restrict the vents.
§ Do not use air blowers on explosive or hazardous gases.
§ Other potential hazards to safety may also be associated with operation of this equipment.
All personnel working in or passing through the area should be warned by signs and
trained to exercise adequate general safety precautions.

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12. Vacuum Power Skid Schematic

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13. Dual Hopper Schematic

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14. Belt Tensioning

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