V400C / V400LP / V600F / V600LP

Electric Pump Driven Vacuum Box System

for weld seam integrity evaluation

Operating Manual

Silverwing UK Ltd Units 30 - 31 Cwmdu Industrial Estate, Carmarthen Road, Swansea, SA5 8JF Wales, UK
t: +44 (0) 1792 585533 f: +44 (0) 1792 586044 e: [email protected] w: www.silverwingndt.com
INTRODUCTION

The portable vacuum box system is used for rapid weld integrity evaluation of welded seams. A
vacuum is generated by the portable electric vacuum pump. A range of vacuum box designs are
available to suit various weld configurations. The most common application for the Vacuum Box
system is the inspection of welded seams within Bulk Liquid Storage Tanks but the system is
also suitable for a wide range of other applications.

General Description
The Vacuum system comprises two basic components, the Electric Vacuum Pump which is
used with any Silverwing vacuum box and operates from an 110v or 220v power supply and the
Vacuum Box which is placed over the welded area for seam leak testing. The vacuum box and
pump are connected together using a 30ft hose. The Vacuum box is available in a number of off
the shelf designs:

 V400C (angled) - Used for internal shell to annular welded areas

- Vacuum up to 20inhg

 V400LP (angled) - Used for internal shell to annular welded areas

- Vacuum up to 10inhg

 V600F (flat) - Used for lap and butt welded areas

- Vacuum up to 20inhg

 V600LP(flat) - Used for lap and butt welded areas

- Vacuum up to 10inhg

Custom vacuum boxes can be produced to suit specific needs

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Date of Release: 30/05/12
 Doc Ref:OM-EVB
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Date of Release: 30/05/12
 The V600F Vacuum Box

Dimensions Length 780mm(30.70inch) x Width 280mm(11.02inch) Height 230mm(9.05inch)

Weight 11kg

Weld test length 600mm (24inch)

Weld type Tank floor lapwelds and butt welds.

Tank Diameter All tank diameters

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The V400C Vacuum Box

Dimensions Length 660mm ( 21inch) - height and width depend on angle

Weight 7kg

Weld test length 400mm (16inch)

Weld type Shell to annular welds.

Tank Diameter 5 meter diameter and over

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Date of Release: 30/05/12
The Vacuum Pump

The vacuum is generated by the portable electric vacuum pump provided.

A vacuum relief valve (mounted on the vacuum box) is pre-set for a maximum vacuum to
prevent damage to the box or the test area while still meeting the requirements of API /
ASME / EEMUA.
V600F / V400 - Maximum Vacuum of 20 in.Hg (9.8 psi)
V600LP - maximum Vacuum of 10 in.HG (4.9 psi)

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Date of Release: 30/05/12
REF DESCRIPTION QTY
1 Body 1
2 Vane 4
3 Shroud 1
4 End Plate 1
5 Gasket 1
6 Muffler Box 1
7 O-ring 2
8 Felt 2
9 End Cap 2
10 End Cap Assembly 2
11 Filter 1
Service Kit - K479

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METHOD OF OPERATION

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Inspection
During testing, illumination must be adequate for proper evaluation and interpretation of the
test.

1. Perform a visual examination of the bottom and welds prior to performing the vacuum
box test.
2. Verify the condition of the vacuum box and its gasket seals
3. Connect the hose to the pump and vacuum box
4. Connect the pump to the power supply specified
5. Flood the weld area with detergent solution such that the area is thoroughly wetted and a
minimum generation of application bubbles occur.
6. Place the vacuum box over the top of the weld area. The open edge of the vacuum box
incorporates a soft neoprene seal so a vacuum can be generated within the box.
7. Ensure the vacuum release valve is closed and switch on the pump.
8. View the weld area through the clear polycarbonate observation window in the top of the
box.
9. A stream of bubbles will indicate any leaks in the weld.
10. A large opening leak will be indicated by a quick bursting bubble or spitting response at
the initial setting of the vacuum box.
11. Open the vacuum release valve when the inspection of that area is complete.
12. The vacuum box test shall have at least 50 mm (2 in.) overlap of previously viewed
surface on each application.

Clean the viewing pane by rinsing with clean cold water. Excessive cleaning using a cloth may
scratch the surface of the viewing pane.

If motor fails to start or slows down significantly under load, shut off and disconnect from power
supply. Check that the voltage is correct for motor and that motor is turning in the proper
direction.

Before storing, please follow proper shutdown procedure to prevent damage to the pump.

1. Turn the electricity supply OFF

2. Disconnect plumbing taking care of O-rings/gaskets
3. Vent all vacuum from the system
4. Disconnect the pump from the pipework
5. Do not stay in line with the airstream
6. Turn the electricity supply ON and run the pump to open atmosphere for
approximately 15 minutes
7. Leave the pump to cool down
8. Disconnect power supply.
9. Plug open ports to prevent dirt or other contaminants from entering product.
10. The unit is now ready for storage

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PUMP SPECIFICATIONS & MAINTENANCE

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Vacuum Pump Maintenance

It is your responsibility to operate this vacuum pump at recommended pressures or vacuum

duties and room ambient temperatures.

Start Up
If motor fails to start or slows down significantly under load, shut off and disconnect from power
supply. Check that the voltage is correct for motor and that motor is turning in the proper
direction. Vane life will be drastically reduced if motor is not operating properly.
Vanes can break or be damaged if motor/pump runs in the wrong direction.

WARNING
Injury Hazard

The pump surfaces become very hot during operation, allow the surfaces to cool before
handling.
Air stream from the pump may contain solid or liquid material that can result in eye or
skin damage, wear proper eye protection.
Flush the pump in a well ventilated area.
Failure to follow these instructions can result in burns, eye Injury or other serious Injury

It is your responsibility to regularly inspect and make necessary repairs to the vacuum pump
in order to maintain proper operation.

Make sure that pressure and vacuum is released from the pump before starting maintenance,
check intake and exhaust filters after first 200 hour's of operation. Clean filters and determine
how frequently filters should be cleaned during future operation. This one procedure will help to
assist the pump's performance and service life.

WARNING

Electrical shock Hazard

Disconnect electrical power supply cord before undertaking any maintenance.

Vent all air lines to release pressure or vacuum, failure to follow these instructions can
result in death, fire or electrical shock.

General maintenance
1. Remove end cap and filters. Inspect filters for tears, cuts, brittleness and excessive
foreign material.
2. Clean filters if in good condition with compressed air. Re-inspect for wear condition.
Set filters aside.
3. Check filter for compacted debris. If debris is present replace filter.
4. Check condition of O-ring, it should be soft and flexible - replace if it is not.
5. Re-install filters or install new filters as required, reinstall end cap.
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Rev:2.0
Date of Release: 30/05/12
Flushing

Flushing this product will remove excessive dirt, foreign particles, moisture or air that occurs
in the operating environment and will help to maintain proper vane performance.
Use only Gast AH255B flushing solvent or other non-petroleum based flushing solvent. Do
NOT use kerosene or ANY other combustible solvent to flush the pump.

1 Remove six end plate bolts. (See exploded view)

1. 2. Use a small hammer to carefully tap end plate to remove. Do NOT use a
screwdriver to pry off.
2. Check that vanes are moving freely in and out of vane sects. Replace vanes if more
than 50% of the vane extends past the vane slot.
3. Remove vanes and clean both sides with fine emery cloth. Clean end-plate with fine
emery cloth.
4. Flush vanes with AH255B solvent and remove all solvent from vanes.
5. 6, Flush body rotor and end plate with AH255B solvent, and then remove all solvent
from each part.
6. Check body rotor and end plate for scoring, If each part is clean and shows no signs
of scoring, re-install parts. If scoring occurs send unit to factory or replace with new
parts.

Check that all external accessories such as relief valve and gauge are attached to cover and
are not damaged before re-operating product.

Shutdown
It is your responsibility to follow proper shutdown procedure to prevent pump damage.

NEVER ADD OIL TO THIS OIL-LESS PUMP.

11. Disconnect plumbing
12. Operate product for at least five minutes without plumbing.
13. Run at maximum vacuum for 10-15 minutes.
14. Repeat step 2.
15. Disconnect power supply.
16. Plug open ports to prevent dirt or other contaminants from entering product.

Servicing
Service Kits are available for this pump. Follow the instructions supplied with the kit. Should
pump require more than a maintenance service, it is recommended you contact Silverwing.

WARNING

Electrical shock Hazard

Disconnect electrical power supply cord before installing service kit.

Vent all air lines to release pressure or vacuum, failure to follow these instructions can
result in death, fire or electrical shock.

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Rev:2.0
Date of Release: 30/05/12
TROUBLE SHOOTING GUIDE

Possible
Low Vacuum High Vacuum Over Heating Motor Overload
Reasons
Dirty Filter X X X
Vacuum Line
Collapsed X X X
Relief Valve Set
Too High X X X
Relief Valve Set
Too Low X
Blocked Vacuum
Line X X X
Sticking Vanes X
RPM Too High X X X
Worn Vanes X
Dirt in Body X X X
Not Wired
Correctly X X

Maintenance Record

Date Procedure Preformed

Doc Ref:OM-EVB
Rev:2.0
Date of Release: 30/05/12