SUPAVAC SV250-V600 VACUUM LOADING PUMP OPERATIONS MANUAL

VERSION 1.3 DATE: 24/09/2009

Factory: 4/15 Cessna Drive Caboolture Queensland, 4510 Australia Phone. 61 7 549555922 Fax. 61 7 54955922

INDEX
Safety First Read this before operating the pump A. B. C. 1. 2. 3. 4. 5. 6. 7. 8. 9. Operational Overview Design Registration Operational Data SV250-V600 Set-up SV250-V600 Use SV250-V600 Switches (Manual Operation) SV250-V600 Timers (Auto Operation) SV250-V600 Accessories (Applications Vary) SV250-V600 Troubleshooting SV250-V600 Maintenance Procedures Important Information Notes on Pneumatic Conveying

SAFETY FIRST
CAUTIONS AND GENERAL SAFETY

This manual contains important information concerning installation, operation and proper maintenance of the Supavac SV250-V600 Slurry Pump. To prevent injury to personnel or equipment damage, this manual should be read and understood by those responsible for the installation, operation and maintenance of the equipment. Isolate, Tag Out and Disconnect the air supply to the unit prior to working on any part of the system. Lift the equipment only at the certified lifting points detailed in this manual. Use properly rated lifting equipment capable of handling the equipment weight. NOTE: Be aware of retained material in the SV250-V600 tank increasing the total weight of the unit. The structure on which the unit is to be installed must be capable of supporting the operational weight of the SV250V-600.

Total operational weight of the SV250-V600 = SV250-V600 Dry weight + (250 litres (full capacity of tank) X Specific Gravity of material being pumped). The unit should be installed in a safe area where walkways, lighting and handrails as appropriate allow safe access for operating and maintaining the unit. Ensure all hoses and pipes are in good condition, correctly rated and certified for the service in which they are to be used, correctly fitted and equipped with appropriate retaining straps. Never weld the pressure vessel section of the SV250-V600 as this will invalidate the certification of the unit. Inspect the unit regularly and replace damaged or worn components only with parts supplied by the OEM Ensure all Guards are fitted securely prior to use. No modifications or Alterations to the structure or control circuitry should be undertaken without the prior approval of Supavac Pty Ltd. Personal injury, machine damage and reduced performance can result from unauthorised modifications or alterations to the SV250V600. Air Pressure applied to the SV250-V600 should NEVER exceed rated pressure

READ THIS BEFORE OPERATING THE SV250-V600

1. The pump MUST have an air supply pressure of at least 550kpa (80psi) while the pump is operating. 2. A 50mm (2) i.d. air hose MUST be used to supply compressed air to the unit. 3. The discharge hose from the pump MUST be rigid self supporting hose with a minimum diameter of 100mm (4). Lay flat hose is not acceptable. 4. The discharge hose must be restrained along its length. Particularly the discharge end of the hose. 5. Contact Supavac directly for advice on set-up or material to be pumped if you are unsure about anything.

A. Overview of SV250-V600 Operation

The SV250-V600 operates as a shuttle system alternately discharging, then loading a wide range of flowable materials. Operation can be either automatic or manually controlled by the operator. The SV250V-600 can pump almost any material from heavy slurry through to almost dry material and there are no moving parts within the tank.

There are three SV250 models available with varying air consumption requirements, 280, 400 and 600cfm. Difficult to transfer materials require high airflow models to achieve efficient transfer of the material. Suction lengths of 50 mtrs and discharges of 1000 mtrs are achievable with this pump.

WARNING
Compressed air can be dangerous. Correctly rated hoses and piping should be used in conjunction with the appropriate safety devices on all connections. The unit is not designed to operate above 785kpa (114psi).

B. Design Registration
The SV250V-600 has a Certificate of Plant Design Registration from Workcover NSW, Australia. Registration Number: PV6-109416/08 Copies of the certification are sent with the MDR of the vessel or available from Supavac on +61 7 54955477. NB: This pump may also require item registration in its State or Country of use. It is the end users responsibility to ensure these Regulations are complied with.

C. SV250-V600 Operational Data

Weight - 410kg (1100lbs) Height - 165cm (65) Width - 130cm (51) Length - 120cm (47) Air consumption is 283l/s (600 cfm) at a maximum of 785kpa (114psi). Throughput Measured water throughput assuming 10 second suction/discharge cycles = 45,000 litres/hour (11,900 US gallons/hour) NB: The actual throughput is affected by the following 1. Type of material being pumped 2. SG of material being pumped 3. Viscosity/flowability of the material being pumped 4. Actual suction and discharge times 5. Suction and discharge head. Contact Supavac directly for advice regarding estimated throughput for any material.

Roll Frame Jet Pack Lifting Point Suction Knife Gate Control Box 4 Check Valve

Suction Flange Tank

Discharge Pipe

Discharge Knife Gate Exhaust

Skid

1. Photo showing main components.

1. SV250-V600 Setup
Before setting up the SV250-V600 check: a) SV250-V600 is undamaged, clean and covers are in position. b) Clean compressed air at a minimum working pressure of 550 Kpa (80psi) and quantity of 600cfm is available at the pump. c) 50mm air hose is available. d) All suction hoses, delivery hoses and pickup nozzle are appropriate for this unit and are serviceable. e) A discharge area has been chosen for the pump, which will not endanger personnel or equipment. Material from the pump can be ejected long distances from the end of the discharge line. f) The pump Does Not require an in line lubricator. g) As with any compressed air operated equipment the use of eye and hearing protection is strongly recommended.

Lifting Point

Jet pack

Knife gate

Knife gate

Exhaust

2. Photo showing Jet Pack, Exhaust and Suction and Jet Pack Knife Gate

Note: For efficient operation of the pump the suction and discharge lines should be the same diameter as the pump (100mm). Increased diameter discharge lines, i.e. 150mm (6) can be employed although a reduction in transfer distance may be observed.

1.1

SV250-V600 Lifting Points There are two methods of lifting the SV250-V600: i) The two lifting lugs on top of the pump ii) The fork lift lifting points provided in the base of the pump

1.2 1.2.1

SV250-V600 Setup with Suction Hose Set SV250-V600 up in a safe and level as possible position near the area to be pumped.

1.2.2 Attach suction hose and nozzle to SV250-V600 and ensure safety clips are in place. Reduce trip and fall hazards and position hoses out of walkways wherever possible. 1.3 SV250-V600 Setup with Delivery Hose

1.3.1 Run out delivery line to the discharge point ensuring there is no danger to personnel from the discharge. Attach delivery hose or pipe to SV250V600. Position hose out of walkways and restrain hose or pipe at regular intervals to ensure it does not move during pumping operations. Quick release fittings on the delivery line are not recommended by Supavac, due to the aggressive nature of the pump discharge. It is advised to minimise elbows and bends in the installation to reduce the effects of hose whip and maximise delivery power. 100mm poly line is an economical discharge line when adequately restrained. Alternately concrete pumping hose or light wall Victaulic steel pipe can be used. 1.3.2 Blow out the 50mm air hose to ensure it is clean and attach to SV250V600. Fit safety clips and ensure the main air valve on pump remains in the off position. Turn air supply on at source.

1.3.3 The pump is now ready to use.

NOTE: ENSURE THE DISCHARGE LINE FULLY SECURED AND DISCHARGE AREA IS CLEAR OF PERSONNEL PRIOR TO ANY OPERATION OF THE PUMP

10

2. SV250V-600 OPERATION
2.1 Ensure discharge area is clear of personnel and Supavac recommend the erection of a safety barricade or warning sign in the discharge area. Ensure any personnel operating the pump are wearing the appropriate PPE. 2.2 Turn air supply on at the pump. Select Auto and the pump will begin a discharge cycle immediately. The pump starts in discharge mode to ensure the vessel is empty prior to the load cycle. The pump is factory set at 10 seconds discharge and 10 seconds suction/load. This can be varied as required, see later section of this manual. 2.3 Slowly introduce nozzle into material to be pumped and continue operation of pump. Listen to the unit operate, an audible change in the unit signals that the vessel is full. If in manual mode select discharge and the unit will empty. 2.4 Once in Auto mode allow the unit to complete a couple of cycles, the Load/Discharge timers can then be adjusted whilst the unit is operating. To adjust the Timers follow the procedure outlined in 4.1 of this manual. 2.5 Check discharge line to ensure it remains correctly anchored. 2.6 When pumping is complete run the pump for a couple of cycles dry to empty the tank. Supavac recommends the pump and all hoses are checked at regularly and at least once per shift for correct operation in aggressive situations. Modes of operation are automatic or manual and the pump can be left running in Auto Mode unattended as dry operation of the SV250-V600 will not damage the pump. Do NOT leave the pump unattended in manual Load mode as extended periods may damage the diffuser tube. Always turn the pump to auto or turn the supply air off if you intended to leave the pump.

There should be a minimum of 80psi on this gauge when the pump is operating

11

Photo 2. Location of the Pressure Gauge

Photo 3. Load/Discharge Switch Auto/Manual Switch

3. SV250-V600 Switches (Manual Operation)

The SV250-V600 operates in Manual by using the switches on the side of the Control Box. See photo 3 for switch location. 3.1 To Use the Switches 3.1.1 Ensure the Auto/ Manual switch is in the Manual position. 3.1.2 Move the Load /Discharge switch to the Discharge position to empty any material in the pump. 3.1.3 Introduce the nozzle into the material to be pumped and move the Load/Discharge switch to the Load position. 3.1.4 When the tank is nearly full move the Load/Discharge switch to the Discharge position, stopping momentarily at the off position when doing so. 3.1.5 Change back to the Load position when all of the material has been emptied from the tank. Continue this process until all of the material has been moved or you wish to operate in Auto mode. 12

Load/Discharge Switch Control air filter water trap Auto/Manual Switch

Discharge Timer

Load Timer

Suction Solenoid Jet Pack Solenoid Discharge Solenoid

Photo 4: SV250-V600 Control Panel

4. SV250-V600 Timers (Auto Operation)

The SV250-V600 operates in Auto by using two pneumatic timers. There are no moving parts in the pump. With experience it is possible to adjust the timers for increased efficiency of operation. Always operate the pump with standard settings until the nature of the material being pumped is fully assessed. The SV250-V600 timers are factory set at 10 second Discharge and 10 second Suction (Load). This is a good average setting for most materials. The timers have a scale on them, but to accurately set the cycle times Supavac recommends that the cycles are timed with a watch. As a general rule the following applies: Shorter suction time: watery/easily pumped material short suction hose lengths (<10m) vessel is overfilling (identified by a change of sound or discharge of material during the suction cycle) Longer suction time: thicker materials/mud/slurry long suction hose lengths (>20m) vessel is under filling 13

Shorter discharge time: watery material/easily pumped short discharge length majority of the discharge cycle there is no material being ejected Longer discharge line: thicker materials/mud/slurry longer discharge lengths (>100m) discharge line not emptying completely each cycle 4.1 To Change the Timer Settings See Photo 4 for timer location 4.1.1 Move the Auto/Manual switch to the Auto position. Ensure that the Load/Discharge switch is in the Off position. 4.1.2 Open control box cover 4.1.3 Adjust either timer to desired setting. CAUTION: timers only operate in the 0-30 second range. DO NOT rotate the timers beyond these settings. 4.1.4 Restart pump and check cycle time with a watch. 4.1.5 Close cover 4.1.6 Monitor pump for a period of time to ensure changes havent impaired the operation of the pump.

5.SV250-V Accessories (Applications Vary)

5.1 Stainless steel Pick-Up Nozzle for ease of operation, attaches to the suction hose, allowing fluidizing of the material being recovered and the operator to stand upright.

Photo 5. Stainless Steel Pick Up Nozzle

14

5.2 Snore Box- attaches to the suction hose for unmanned operations. Stops large or unknown submerged items from blocking the suction hose.

.
Photo 6. Strainer and Snore Box

6. SV250-V600 Troubleshooting
Before checking anything else ensure the correct pressure and quantity of compressed air is being supplied to the pump. Pump not cycling correctly Low supply air pressure Ensure correctly rated compressor is used. Ensure hoses are correct diameter Unblock discharge line as per Section 7.1 Unblock suction line as per Section 7.2 Clean or replace filter as per Section 7.3 Unblock suction line as per Section 7.2 Replace damaged section of hose. Check all fittings have washers inserted correctly. Clean nozzle and housing as per Section 7.4 Add water to the material as required. Ensure correctly rated compressor is used. Ensure hoses are correct diameter Clean or replace filter as per Section 7.3 Contact Supavac for service.

Blocked discharge line Blocked suction line Blocked filter Pump operating correctly but not loading material Blocked suction line Suction hose collapsed or leaking

Blocked Jet Pack nozzle

Pump not operating

Material too viscous for the pump Low supply air pressure

Blocked filter Control system fault

15

7. SV250-V600 Maintenance Procedures

In use the SV250-V600 requires minimal maintenance. However the following procedures are recommended. Daily: Check pump is undamaged; cover and all safety clips etc. are in position. Ensure the suction check valve is serviceable. Check by removing the suction hose and checking the valve can operate freely and there is no foreign matter obstructing the valve. Check the discharge hose is serviceable and correctly anchored and that the discharge area is free from personnel and safe for the days operations. Check the suction hoses for damage or wear and replace as necessary. Check the air supply hose and ensure it is serviceable. Check and clean the primary, secondary and timer filters and replace as required. Check the lubricator and drain any residue water from the bowl ensuring there is a sufficient level of air tool oil (Shell Tellus 20) or similar is evident. Once pumping has commenced it is recommended practice to observe for several cycles to ensure all components are operating correctly. Service time is 5 minutes.

7.1 Blocked Delivery Line In the event of a blocked discharge line the pump may retain pressure. A check valve fitted to the suction inlet after the Knifegate valve acts as a failsafe and prevents material discharge (blow back) through the suction line. To remove a blockage from the discharge side of the pump: 7.1.1 Isolate compressed air to the pump as per site procedures 7.1.2 Remove cover from pump 7.1.3 Relieve stored pressure in pump by operating the pressure relief valve situated just behind the Jet Pack rotary ball valve. (Photo 7) 7.1.4 Carefully remove discharge line and clear the blockage. 7.1.5 Remove the suction hose at the pump and ensure the check valve is operational and clear of foreign matter. 7.1.6 Replace hoses and resume normal operation

16

Pressure Relief Valve

PRV Easing Lever

Photo 7. Pressure Relief Valve and Easing Lever

7.2 Blocked Suction Line If the suction line of the pump is blocked usually there will only be residual vacuum in the line, although if the hose is operating with a high vertical lift you will have that head of material to consider. To remove blockage from the suction line: 7.2.1 Isolate compressed air to the pump as per site procedures. 7.2.2 Relieve stored pressure in pump by operating the pressure relief valve situated just behind the Jet Pack rotary ball valve. (Photo 7) 7.2.3 Locate the obstruction and carefully remove the suction hoses commencing from the Pick-Up nozzle (It may be necessary to apply moderate force to break the vacuum) clear the blockage. 7.2.4 Remove the suction hose at the pump and ensure the check valve is operational and clear of foreign matter. 7.2.5 Replace hoses and resume normal operation 7.3 Checking Oil and changing air filter

Main Filter

Lubricator

Photo 8. Location of Filter and Lubricator

17

The filter is located either in or under the control box at the front of the pump. (Photo 8)To access the filter: 7.3.1 Isolate compressed air to the pump as per site procedures. 7.3.2 Remove the access cover (if required) 7.3.3 Check there is no residual air pressure in the tank 7.3.4 Unscrew metal retaining ring from air filter housing. 7.3.5 Gently slide the clear plastic bowl from air filter. Be careful not to lose or damage the o-ring from top of the plastic bowl. 7.3.6 Unscrew the black plastic element support and remove the element, clean or replace if required. 7.3.7 Replace with new filter element (available from Supavac) in reverse order. Ensure the o-ring is fitted to the top of the clear plastic bowl. 7.3.8 If necessary replace the timer filter element (located in the control box photo4). 7.3.9 If necessary top up the lubricator with light air tool oil 7.3.10 Replace all components and resume normal operation.

7.4 Cleaning Jet Pack

Jet Pack Housing Jet Pack Pins

Diffuser Tube

Upper Triclover Clamp and Seal

Lower Triclover Clamp and Seal Photo 9. Jet Pack Assembly, pins and clamp

The Jet Pack may require cleaning after prolonged use or if the vessel has been overfilled. To clean the jet pack and nozzle: 7.4.1 Isolate compressed air to the pump as per site procedures 7.4.2 Check the system to ensure there is no stored pressure in either the pump or discharge line. 7.4.3 Remove the two locking pins in the Jet Pack housing (photo 9). 7.4.4 Unscrew the Upper Tri-clover nut and remove the ring clamp from the diffuser tube taking care not to damage the seal. 7.4.5 Loosen the lower Tri-clover nut and swing the exhaust elbow away from the diffuser tube. 7.4.5 Slide the diffuser tube away from the Jet Pack housing taking extreme care not to damage the nozzle. 7.4.6 Clean as necessary, and ensure the venturi and the opening to the tank are free from residue build up or obstructions. 7.4.7 Replace the Jet Pack housing in reverse order. Ensure seals are in the correct positions. 18

IMPORTANT INFORMATION.
If the discharge line is going to exceed 80 metres the following procedure must be followed to ensure that the SV250V-600 operates to its maximum potential. If not followed the performance of the SV250V-600 will be below optimum.

1. Disconnect air line to Rotary Ball Valve

2. Remove the Triclover clamp (A) that attaches the Exhaust valve to the Discharge Flange and loosen the Triclover clamp at the top of the Exhaust elbow

3. Swing the Exhaust elbow away from the Discharge Flange allowing adequate room to attach a Discharge hose and tighten the Triclover clamp at the top of the Exhaust elbow.

19

4. Using the Triclover clamp and seal that has just been removed, secure the End Cap (supplied) to the back of the Discharge Flange and tighten.

5. Attach the Triclover to 3BSP adaptor (supplied) to the exhaust valve using the Triclover clamp and seal supplied and tighten.

6. Screw in to the adaptor a suitable hose connection and tighten.

7. Connect the airline to the Rotary Ball Valve and attach Exhaust Hose and test the pump.

20

NOTES ON PNEUMATIC CONVEYING SUPAVAC pneumatic conveying units have the capability of recovering material by two modes- the first being pure vacuum while the second is air conveying. As a general rule pure vacuum would be used for removing sludge from beneath liquid- or for rapid liquid or slurry loading within close proximity to the machine. In this mode, the vacuum tube is totally submersed in the liquid and only material (no air) transports through the line. The maximum vertical suction lift from the machine to the liquid surface cannot exceed 9.2 meters at sea level assuming water is the liquid. Horizontal suction distances would be greater. For materials of a higher density than water, these figures must be reduced accordingly. This mode is a conventional pumping technique with the material being displaced by negative pressure. However SUPAVAC machines can transcend conventional pumping techniques by pneumatically conveying materials. Pneumatic conveying is a method of handling materials by utilizing high velocity airflow with a pipeline. This requires sufficient air velocity to pass the material being picked up to capture it and convey it through the vacuum tube to the machine. The air velocity is kept up by not fully submersing the nozzle or by allowing air to the pick-up point via a snorkel tube attached to the nozzle. The advantages of this technique are: Suction lifts up to 25 meters+ vertically can be achieved Materials can be liquid dry or damp Particle sizes of up to 80% of the suction hose diameter can be conveyed Horizontal suction distances in excess of 60 meters can be achieved Fibrous, waxy and heavy sludge can be handled Powders and solids can be handled as well as wet materials

There are also applications where a vacuum fluidizing tube should be used which combines the benefits of pure vacuum and pneumatic conveyance when removal of material from beneath liquids is required where the distance exceeds the limitations of pure vacuum. All SUPAVAC units utilize high airflow and vacuum (up to 25HG+ at 100Psi) to ensure high performance. The SUPAVAC range of equipment is designed to enable the user to either convey recovered material into a collection vessel where the contents are discharged under gravity or alternatively the recovered material can be discharged under gravity or alternatively the recovered material can be discharged under pressure, through a pipeline. Two modes of positive pressure discharge are used in SUPAVAC machinesdense phase and lean phase pneumatic conveying. The later can achieve vertical heads in excess of 35 meters and horizontal discharge distances of over 1000 meters. The absence of any electrical supply in SUPAVAC machines makes them useful in restricted or potentially hazardous areas. 21

22