Turbo pumps are a critical component of many industrial processes including surface treatments, manufacturing television and monitor picture tubes and semiconductor processing. They use a rotating turbine rotor to create vacuum by hitting gas molecules and directing them toward the exhaust.
While there are a few ways that a turbo pump can fail, most are fairly simple to fix and will require only some basic tools.
Vacuum Processes
Vacuum processes are used in various fields of science and engineering. These processes are designed to operate with extremely low atmospheric pressure, and the vacuum pumps that are used to achieve this condition must be able to perform as efficiently as possible for long periods of time. The process of achieving a vacuum can involve a number of different components, including gauges, vapor jet and pump systems, vacuum traps and valves and extensional piping. The system must also be able to sustain a constant level of vacuum for the duration of its operation.
The performance of vacuum pumps is dependent on a number of factors, including the design of the pump, oil quality and the amount of moisture in the system. In addition, it is important to maintain proper maintenance on the vacuum system in order to ensure that it achieves its desired level of vacuum. Performing regular visual inspections of the vacuum pump can help to identify any potential problems with the system and determine when it is time to contact an experienced professional for repair services.
One of the most common problems encountered with rotary vacuum pumps is backstreaming. When this happens, the pump oil can contaminate the vacuum system and hinder its ability to reach the ultimate vacuum. In most cases, this problem can be prevented by using the correct pump oil and monitoring it for signs of contamination.
Another important factor in ensuring that the vacuum pump system operates properly is the proper sealing of all connections. Leaks in the sealing process can result in loss of vacuum, and it is vital that all connections are tightened and resealed on a regular basis to prevent this.
Performing these simple maintenance tasks can greatly extend the lifespan of the vacuum pump, but it is important to recognize when a pump is exhibiting signs of problems that may require more extensive repair services. The most obvious warning sign is a noticeable change in the performance of the vacuum pump. For example, a change in amp draw can indicate that the pump is working harder to achieve a certain level of vacuum, which could lead to premature wear and tear on the motor and other parts.
Industrial Applications
Many industrial applications require specialized equipment and processes that are not found in other industries. For example, a pump used in manufacturing may be designed to handle corrosive materials that are difficult to pump. Likewise, industrial devices like computers or smartphones are designed for use by large numbers of people and companies, so any failure could have far-reaching implications. In contrast, commercial and consumer applications are typically less risky and have a much smaller scope of operation.
A typical vacuum system is made up of a pump or multiple pumps plus connecting tubes, valves and control systems. While most pump manufacturers offer a range of standard pumps, many also provide custom models that are specifically designed for industrial applications. These are often the best choice for industrial applications because they can be tailored to specific processes and have built-in features that address common problems seen in the field.
For example, if you are using your pump to pump corrosive gases, you need to take special precautions to protect the motor / bearing area and rotor against corrosion. The solution is to install a special fore-vacuum gas valve that admits a defined inert gas into the motor / bearing area. This gas is then pumped down with the corrosive gas through labyrinth seals and back to atmospheric pressure when the pump stops running.
Another issue that can be easily addressed is excessive vibration or a noisy pump. Vibration and noise are usually caused by gradual wear that causes the shaft position to shift slightly until rubbing develops between the gears or impeller. If this continues, general damage to the casing and gears is likely to occur.
At PSI, we have experience with a wide variety of industrial pumps, including air-operated double-diaphragm, bellow, rotary vacuum and cryogenic pumps. We have repaired a number of different manufacturers’ pumps, including Beach-Russ, Dayton, Gardner Denver and Mitsubishi. We are also experienced with repairing and maintaining abrasion-resistant ceramic, stainless steel and Hastelloy vacuum pumps. Our technicians are available 24 hours a day to service your industrial pumps. Contact us today to learn more about our services and how we can help you protect your investment in a high-quality vacuum pump for your industrial application.
Maintenance
A good vacuum pump needs proper maintenance to keep it working at its best. Regular tune-ups can identify future service issues and prevent costly repairs or unplanned downtime. Preventative maintenance also helps you extend the life of the equipment by keeping it running to the specifications it began with.
For example, if you notice your vacuum pumps have to work harder to reach the same pressure level, it may be a sign that their seals are wearing out. Inspecting the seals regularly and replacing them when necessary will keep your equipment running at its maximum performance and lifespan.
A leaking shaft seal is another major issue that must be repaired immediately. Leaking shaft seals can damage the shaft and lead to expensive replacement costs. In addition, a damaged shaft will also cause the pump to operate outside of its tolerances and can potentially create dangerous vapors or debris.
Inspecting the seals and replacing them when needed will help extend the life of your vacuum pumps. Inspecting the shaft seals and replacing them when necessary will help extend the life of your vacuum pumps.
Other common problems include high horsepower or an inability to reach the specified vacuum pressure. These are typically easy fixes that can be performed in-house. For example, a high horsepower problem can be caused by an incorrect V-belt tension or misalignment, a restriction in the suction piping, or operating the equipment at a higher speed than recommended.
When a mechanical seal fails, it can cause severe damage to the pump’s rotor assembly and reduce its lifetime. In many cases, it’s much less expensive to replace the rotor assembly than it is to replace the entire pump.
If you suspect your mechanical seal has failed, the first step is to remove the rotor from the pump and inspect it. Look for visible signs of wear, such as scratches and dents on the surface of the rotor and its hub. It’s also a good idea to perform an inlet vacuum test. This will allow you to determine whether or not the rotor is leaking by measuring the vacuum difference at the inlet ports.
Replacement Parts
Designed to meet your maintenance needs, these kits are complete with the parts and tools needed to repair the Edwards turbo molecular pump. These repair kits contain all original replacement parts allowing your maintenance team to start work with all of the materials needed for a successful repair reducing downtime and saving you money in the long run.
These units employ five-axis (2x, 2y and z orientation) active magnetic bearings (located on either end of the rotor shaft) with position sensors that provide variable magnetic field control. Because they do not use mechanical bearings these TMP’s require no lubrication and have very low transmission vibration.
These systems are designed to pump corrosive gases that would quickly destroy lubricated mechanical bearings. They also do not have a mechanical seal and are limited to a maximum pressure of 30 bar.
