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PROCESS TECHNOLOGY

Optimize your vacuum

distribution network for
a maximum point-of-use
vacuum - part 1
Vacuum
piping
Frank Moerman, European Hygienic Engineering & Design Group - Belgium

Air leaks and pressure drop in the vacuum distribution Monitor for
system result in poor vacuum at the points-of-use. airtightness
Valves can be provided at several
Properly designed and installed vacuum systems places in the vacuum line, to
are less susceptible to fluctuations in production determine if air leakage occurs in
vacuum load, which can result in higher productivity, the upstream piping of the vacuum
system. However, too much isola-
better-formed products and enhanced product quality
tion valves increase pressure drop.
or safety. As an example, in the semiconductor The most commonly used test
industry, oxygen from an air in-leak can chemically methods to determine the presence
of air leaks are the following:
react with silane to produce sand, SiO2, not the
desired semiconducting solid. In the food industry, A pressure test with oil-free
improper vacuum during packaging may compromise nitrogen allows to measure the
the safety of the food product. decrease in pressure over a cer-
tain period of time (usually 24
h) in the entire system. Because
leakage characteristics differ
between a pressure-test and a
vacuum operation, particularly in
components, such as valves and
flanges, pressure testing is only
successful to find large leaks as it
does not discover the small leaks
that inevitably develop as the
system ages (Umrath et al., 2007;
Hesser, 2008).
With the foam-spray test, the
contractor can register the forma-
tion of bubbles in a soapy solu-
tion applied to leaking joints of
a system under pressure (Umrath

Design for airtightness

Vacuum lines must be completely airtight to guarantee their
proper functioning to a maximum. Vacuum leaks in the piping
components of the vacuum system could lead to insufficient
vacuum capacity, and they also can allow non-condensable
gases into the system as well as condensable contaminants.
Even small quantities of both can take up large volumes, requir-
ing higher-capacity vacuum sources, as well as bigger system
components. An increase in the non-condensable load may also
cause an unstable vacuum, because non-condensable loads must
always travel through the vacuum source.
To minimize losses over the length of the suction line, the
vacuum source should be installed in a technical corridor or
mechanical room as close as possible to the process for efficient
vacuum. Too long vacuum distribution lines increase the risk
for air leaking within the vacuum system. The consequence
is that the vacuum source must operate at an elevated level of
vacuum to compensate for that leakage of air into the vacuum
system. However, higher vacuum levels may open more leaks Fig. 1: ultrasonic leak detection.
(Bott, 2006; Hesser, 2008).

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Smallest
detectable Quantitative the location of the leak site. The advantages
Method Test gas Pressure range
leak rate measurement of ultrasonic leak detection include versatil-
mbar.l/s ity, speed, ease of use, the ability to perform
Air and other tests while equipment is running, the ability
Pressure drop test 10-4 Positive pressure Yes to find a wide variety of leaks and its accu-
gases
racy (Senternovem, 2010).
Foaming liquids Air and others 10-4 Positive pressure No In table 1 a comparison is made between
different air leak detection methods, more
specifically their air leak detection potential.
Pressure rise test Air 10-4 Vacuum Yes

Air and other

Bubble test
gases
Helium leak
helium
detection
Ultrasonic
Air and others
microphone
Table 1: comparison of leak detection methods (Umrath et al., 2007).
et al., 2007).
In the rate-of-rise test, the entire system
is lowered to a vacuum deeper than operat-
ing pressure, and the rise in pressure is
monitored over a period of time. Given the
system volume, leakage can then be calcu-
lated accurately. It is recommended to run
this test on individual components of the
system (piping, equipment, filters, knockout
pots, etc.) as accurately as you can. The rate-
of-rise over 24 hours for a given component
of the vacuum system should be 10% or less
of the operating vacuum absolute pressure
(Fay et al., 2000; Hesser, 2008; Umrath et
al., 2007).
A vacuum test with a cream applied to all
joints and potential leak points also is used
to find air leaks. The cream will be sucked
into the opening and the leak site will be
easily observed.
During leak detection by means of a trace
gas, helium is injected onto expected leaking
parts of the vacuum system, after which the
helium is allowed to enter and accumulate
within that system for a period of time.
10-3 Positive pressure No
10-12 Vacuum,
Yes
10-7 Postive pressure
10-2 Positive pressure No
Fig. 2: use a
wye or swept
T (with 30-60
angle between
both branches)
instead of a tee.
Then the vacuum system is opened to the
leak detector, and the helium-content is
measured at the inside of the vacuum system
(Senternovem, 2010).
In ultrasonic detection, an ultrasonic detec-
tor is used to register the sound of in-leaking
air. An ultrasonic acoustic detector can
recognize the high-frequency hissing sounds
associated with air leaks. Portable ultrasonic
acoustic detectors consist of directional
microphones, amplifiers, audio filters, and
usually have either visual indicators or
earphones to detect leaks. The principle
behind ultrasonic leak detection is simple.
In a vacuum leak, the leak flows from a
high-pressure laminar to a low-pressure
turbulent flow. That turbulence generates a
noise which contains a broad spectrum of
sounds ranging from audible to inaudible
frequencies. An ultrasonic sensor focuses
in on the ultrasonic elements in the noise.
Because ultrasound is a short wave signal,
the sound level will be loudest at the leak
site. By generally scanning around a test
area, it is possible to very quickly pinpoint
Design for minimal pressure
drop
Pressure drop is the difference between the
vacuum level at the vacuum source inlet
and the vacuum level at the end-use point.
In rough vacuum, pressure drop in piping
may not be larger than 50 mbar. In general,
allowable pressure drop for piping systems
is of the order of magnitude of 10% of the
absolute vacuum pressure. This means that,
for example, a 10 mbar vacuum system can
tolerate only 1 mbar of line pressure drop.
As depth of vacuum increases, the allowable
pipeline pressure drop is proportionally less.
If the system piping and equipment do not
have an adequately-low pressure drop, then
no matter how big the vacuum-generating
device is, it can never achieve the desired
level of vacuum (Fay et al., 2000; Sentern-
ovem, 2010).
Too long vacuum distribution lines are
prone to higher pressure drops due to fric-
tion. But apart from too long pipe runs, inad-
equate (restrictive) vacuum piping diameter
is also a major contributor to pressure drop.
Proper pipe dimensions will help to limit
vacuum fluctuations. As a rule of thumb,
on single vacuum pump applications, the
diameter of the vacuum pump inlet should
be maintained as far into the process as
possible. If the vacuum system has to be
installed further away from the process, it is
even recommended to oversize the vacuum
line upstream of the vacuum source to mini-
mize the overall line pressure drop. With
increasing depth of vacuum, the vacuum line
sizes increase. When several pump systems
operate in parallel on a common manifold,
the line size of the manifold should be
minimal equal to the sum of the individual
vacuum pump inlet cross-sectional areas
(Bott, 2006).
With regard to pressure drop reduction,
vacuum piping with smooth interior walls
is superior to rough walled pipe. Further,
the pipe parts to build the vacuum system
should be rather long than short. Larger

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numbers of short pipes ask for more joints,

increasing the risk for vacuum leaks. Piping
runs should be as straight as possible. Every
bend, every change in direction, etc. adds
to pressure drop. Elbows should be kept
to a minimum and, where they are neces-
sary, long-radius elbows are preferable to
90-degree short-radius turns. Wherever two
lines come together, to lower pressure drop,
a wye or swept T (positioned horizontal, on
their side) (Fig. 2) should be used instead of
a tee (Bott, 2006; Hesser, 2008). Fig. 4: gate
Adequate piping support should be pro- valve.
vided to avoid liquids accumulating at low
points of the pipe system and to minimize
external loads on the vacuum source. But because they are more prone to leakage, they uids and solid particles from the vacuum
inversely, if not sufficiently supported, should be kept short (Aglitz et al., 1995; air stream upstream of the vacuum pump
vibrations generated by the vacuum source Mattox, 2009). inlet. It is important to have the correct
also can cause air leaks in the upstream To minimize pressure drop, all piping type, configuration and porting on receivers
vacuum piping, if that piping is not suf- between the process and vacuum source and separators, to ensure adequate liquid
ficiently supported. Proper piping support should have as few valves and fittings as separation and low pressure drop. Many
also must intercept the external load causedpossible, and all connections should be kept separators have minimum and maximum
by thermal movement (Fig. 2). as short as possible. Isolation valves and velocity requirements for optimum separa-
The vacuum system designer must take check valves should be full-port and match tion efficiency. It is important to follow these
care that all joints in piping, whether the diameter of the system piping. The port guidelines to provide maximum protection
flanged or screwed, should be free of straindiameters of standard ball valves are too for the vacuum pump (Bott, 2006).
and checked for leaks (Fig. 3). Improperly restrictive for vacuum applications, and
installed piping can result in misalignment,check valves may restrict the flow if they Monitor for minimal
vacuum pump failure, and general operat- become lodged or fail to open completely. pressure drop
ing problems. All piping connected to the Full-port ball, gate (Fig. 4) or butterfly That pressure drop can be measured by
vacuum source must be installed without valves provide excellent flow characteristics means of an accurate vacuum gauge. First,
imposing any strain on the system compo- with very little restriction, and also low- the vacuum level at the inlet of the vacuum
nents. Vibration from the mechanical pump pressure drop check valves are available on source is monitored, and then the vacuum
should be isolated from the vacuum system the market (Bott, 2006). level at the point-of-use (or as close to the
by means of flexible bellow connections that Most vacuum pump technologies require point-of-use) is measured with the same
also allow corrections for misalignment. Butinlet filters to remove particulates from the vacuum gauge (Bott, 2006). <<
incoming air stream. A
permanent low-pressure-
drop strainer should be References
Aglitz, J., Bhatnagar, R., Bolt, D.E. & Butzbach, T.L.
installed to save equip- (1995), Installing Liquid-Ring Vacuum Pumps,
ment and production Chemical Engineering, 102 (11), 132-138.
Bott, D. (2006), Evaluate pressure drop in vacuum
downtime. Filter element system, PlantServices.com, 5 p.
loading increases pres- Fay, T., Kraus, J.N. & Levy, M.J. (2000), Improving
sure loss and can be easily vacuum systems, Chemical Engineering, Vol. 107, (10),
pp. 86-91.
avoided with proper pre- Hesser, H. (2008), Take the pressure off vacuum
ventive maintenance. systems, Chemical processing, 71 (2), 20-23.
Improperly sized filters Mattox, D.M. (2009), Vacuum technology: Mechanical
Vacuum Pumps, Education Guide to Vacuum Coating
with small port diam- Processing N97, Albuquerque, United States, Society of
eters also can be a major Vacuum Coaters, p. 53-54.
source of restriction. The Moerman, F. (2013), Hygienic design of vacuum
systems, book chapter in progress, 23 p.
filter manufacturer must Senternovem (2010), Vacumsystemen, brochure
check for proper sizing VNCI, Vereniging Nederlandse Chemische Industry, 8 p.
Umrath, W., Adam, H., Bolz, A., Boy, H., Dohmen,
and installation (Bott, H., Gogol, K., Jorisch, W., Mnning, W., Mundinger,
Fig. 3: the vacuum system designer must take care that 2006). H.-J., Otten, H.-D., Scheer, W., Seiger, H., Schwarz, W.,
all joints in piping, whether flanged or screwed, should At times it is neces- Stepputat, K., Urban, D., Wirtzfeld, H.-J., Zenker, H.-J.,
(2007), Leaks and their detection, Fundamentals of
be free of strain and checked for leaks (Hesser, 2008). sary to use receivers and Vacuum Technology, Cologne, Germany, 200 p.
separators to remove liq-

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