Air Ejector PDF

MODEL No.
62C32C
CONDENSER AIR REMOVAL HOLDING SYSTEM
The Unique VIP Service Advantage
Value, Integrity, Professionalism and Service
FOREWORD
This manual is designed to provide the system owner/operator with detailed information on the
proper installation, operation, maintenance, and troubleshooting of a Steam Ejector Vacuum
System. Your system is one of many thousands of similar units provided by Unique Systems, and
the original developer of this technology, the Elliott Turbomachinery Company. In 1985, Unique
Systems purchased the Process Equipment Product Lines from Elliott, and your system is an end
product of almost 100 years of ejector testing and development work.
This manual is written for and to be used with the following equipment:
SYSTEM MODEL 62C32C

CONDENSER AIR REMOVAL HOLDING SYSTEM
15 SCFM HOLDING CAPACITY (PER ELEMENT)
SERIAL No. 09-1138

This system serial number is extremely important. It is the means by which Unique Systems, the
designer and manufacturer of this equipment, can identify all information about your system. Please
refer to this number on all communications with Unique.
*** CAUTION ***

This system has been designed in accordance with applicable U.S. Codes and Standards. It is a piece of
process equipment that utilizes high pressure/high temperature steam, high pressure cooling water, and (on
some models) electrical components that can cause severe injury or death if misused, operated improperly, or
operated in excess of design conditions. DO NOT operate this equipment other than in accord with these
instructions. Particular care should be taken when operating this equipment, as surface temperatures in
excess of 120 F are present and may cause severe burns if touched with bare skin. USE EXTREME CAUTION
when manually operating steam valves. Improper closing of isolation valves before or during operation may
cause safety relief valves to pop open. Notice is hereby given that it is the responsibility of the installation
contractor to pipe relief valves away from operator areas and vent to a safe location. In no case should
maintenance be attempted while the system is in operation or while the steam supply is on or the header is
under supply pressure. All manual and automatic steam isolation valves must be locked closed and tagged
prior to any ejector component maintenance or removal.
STUDY THIS MANUAL!!

All operations and maintenance personnel are strongly encouraged to read and understand the
contents of this manual. It includes detailed information on many system components (including
component I&O manuals), drawings, and performance data that will be needed in the routine
operation and maintenance of this equipment.
Note that it is not possible to cover in this manual every conceivable operational contingency that
may occur. If circumstances develop or problems occur that cannot be diagnosed and solved with
the information in this manual, contact Unique Systems directly for assistance.
*** WARNING ***

This equipment has been designed and manufactured for the process and utility conditions specified by the
purchaser. It is warranted by Unique Systems for operation under those conditions. The user is hereby
advised that making any changes to the design, materials, dimensions, or configuration of any component(s)
may result in improper performance or hazardous conditions. Any changes or alterations to this equipment
made without the express, written consent of Unique Systems Inc. will void the system warranty.
PERMISSION TO MAKE COPIES OF THIS MANUAL

Permission is hereby granted to the owner of the
equipment described and referenced herein by
Serial Number, to make copies of the contents of
this manual sufficient for operation and
maintenance needs. This manual is considered
PROPRIETARY by Unique Systems Inc., and
copies may not be made or distributed for persons
or organizations for whom it is not intended, or
used in a manner detrimental to the interests of
Unique Systems, or its OEM customers.
2008 by Unique Systems Incorporated
TABLE OF CONTENTS
INTRODUCTION
SECTION 1
Air Removal Systems The Application

Ejectors General Principles of Operation
Ejectors Single & Multistage Operation
SHIPPING & RECEIVING INSPECTION
SECTION 2
Shipping Information
Receiving Inspection
Storage Recommendations for On-site
Cleaning & Touch-up
INSTALLATION
SECTION 3
Foundation Requirements
Piping Connections
Suction
Cooling Water
Vent
Steam
Drains & Traps
System Installation & Check-Out
Mechanical
Electrical
OPERATION
SECTION 4
Typical Air Removal System Start-up Procedure

Steam Pressure & Temperature
System Shut Down Procedure
Normal System Operation Continuous and Cyclical
ROUTINE MAINTENANCE
SECTION 5
System Component Checks

Replacement Parts
QuickCheck Nozzles
TABLE OF CONTENTS
TROUBLESHOOTING & TESTING
SECTION 6
Is it the Ejector System?

Ejector Problems Symptoms & Corrections Methods
Poor Vacuum Motive Steam Conditions
Poor Vacuum Mechanical Condition of Ejector Components
Poor Vacuum - Improper Drainage
Poor Vacuum Excess Air Leakage & Testing
System Component Problems
Erratic Hogger Performance
GETTING HELP
SECTION 7
Calling & Online Support

Field Service Engineering
SPARE PARTS
SECTION 8
Ejector Bills of Material

Recommended Spare Parts List
SYSTEM DESIGN SPECIFICATIONS
SECTION 9
Data Sheets
Performance Curves
DRAWINGS
SECTION 10
CATALOG CUTS & COMPONENT MANUALS
SECTION 11
SPECIAL INSTRUCTIONS
SECTION 12
FORMS RECEIVING & STORAGE INSPECTIONS
SECTION 13
WARRANTY & CLAIMS
SECTION 14
QC DOCUMENTATION
SECTION 15
SECTION 1
INTRODUCTION
AIR REMOVAL SYSTEMS THE APPLICATION
Steam ejectors have been employed for removing air from steam surface condensers since the beginning of the
industrial revolution and the advent of steam power. They are the simplest, most reliable method known of
pumping gases. In the air removal application, ejectors and condensers are employed to evacuate air (and any
other non-condensable gases) from the steam space of the main condenser that services a steam turbine. This
gas removal is done for the purpose of eliminating the insulating effect that non-condensable gases have on the
transfer of heat from steam through the tubes to the cooling medium. Without a vacuum system, air would
severely reduce the efficiency of the heat transfer, resulting in the condenser surface area increasing many times
for a given steam load.
An Air Removal System is designed to do just that remove air. It does NOT create the vacuum in a
condenser. The condensation of steam from a vapor to a liquid actually creates the vacuum (a volumetric
reduction on the order of 30,000:1 from 1 HgA to 30 HgA). This is an important point for the operator to
understand. The ejector system is designed to remove air, plus water vapor of saturation at the point called the
air vent temperature, which is typically sub-cooled 7.5 degrees F below the saturation pressure of the main
condenser by a special sub-cool tube bundle in the condenser. System capacity is usually determined by the
recommendations given in the Heat Exchange Institute Standards for Steam Surface Condensers (latest
edition), which gives recommended venting system capacities based on steam load, number of shells, and
number of main openings in the main condenser shell. It should be noted that these recommendations are not
always followed by every condenser manufacturer, and the actual capacity of your specific system is listed on the
Ejector System Data Sheet under SECTION 9 of this manual.
A typical Air Removal System for steam condenser service consists of two major components a rapid
evacuator ejector (often called a hogger), and a multi-stage, multi-element holding system.
The hogger is a single stage ejector of relatively large capacity that is designed to quickly evacuate the air from
the condenser shell prior to steam being introduced to the turbine. Typical evacuation times are on the order of
30 minutes to 10 HgA (see the HEI Standards table for Hogger Capacities). Hogger ejectors are often designed
based on the steam space volume and specified pump-down time, which can result in rather large ejectors and
high steam consumption for large wet surface condensers, and especially for Air Cooled main condensers. Due
to the very high generated noise levels of these ejectors, a discharge silencer is almost always included for noise
attenuation. The hogger is always vented to atmosphere, since the relatively short operating cycle does not result
in the wasting of large amounts of condensate. Note that hoggers are not always included in every air removal
system. On smaller systems (less than 7.5 SCFM), it is common to evacuate the condenser using only the
second stage ejector for this duty.
The holding system typically consists of two elements with two ejector stages for each element. It is designed to
remove air that leaks into to the condenser from various sources during normal turbine operation. These two
stages are separated by an intercondenser, and the second stage discharges into an aftercondenser for noise
attenuation and condensate recovery. Each two stage element is sized (usually) for 100% of the specified air
removal capacity as recommend by HEI (or as required by the clients engineer). Both elements can be mounted
on a common inter/after condenser, or on separate condensers. There are a number possible configurations, but
the most common is as shown in Figure 1 below.
FIGURE 1
Typical Two Stage/Twin Element Ejector Air Removal System
The first stage ejector draws air and vapor from the condenser sub-cool bundle air off-take, compresses it from
design pressure to an interstage pressure. Steam is condensed in the intercondenser, and the second stage
compresses the gases from this point up to atmospheric pressure. Typical system design requires only one
element at time to operate, and the condensers are sized accordingly. It is not uncommon, however, for the
system to be designed such that both elements can be operated simultaneously (see the Ejector System Data
Sheet for specific details on your system). Be sure to check the Ejector Spec Sheet to confirm that simultaneous
operation is possible BEFORE attempting to do so.
STEAM EJECTORS
OPERATING PRINCIPLES
Steam jet ejectors operate on a mass-velocity principle. The propelling steam expands isentropically through a divergent
nozzle, converting its pressure energy into velocity energy (ranging from 2,500 to 5,000 ft/sec). The mass of highvelocity steam is discharged from the nozzle in a directed flow through an air chamber and into a convergent-divergent
diffuser. As the steam passes through the air chamber it comes in contact with, and entrains, a definite mass of the
vapors to be evacuated. It imparts to this mass a portion of its own velocity, and the resultant total mass at reduced
velocity enters the diffuser where its velocity energy is, in the greater part, converted into pressure, thus permitting the
resultant mass to be discharged at a pressure considerably higher than the pressure in the air chamber. The entrained
mass is thus compressed from a low absolute pressure to some higher absolute pressure.
SINGLE- & MULTI-STAGE EJECTORS

When all of the desired compression is accomplished in a single diffuser, the unit is known as a single-stage ejector. A
limited amount of compression may be accomplished more economically in a single-stage ejector than in a multi-stage
unit.
As with other gas compression apparatus, energy may, in some cases, be saved by affecting compression in several
stages. Where the vacuum is high, the discharge pressure high, or the steam pressure low, multi-stage compression is
desirable.
In a multi-stage ejector, the total amount of compression desired is accomplished by dividing between two or more
ejectors operated in series. The ejector which the entrained gases first enter is called the first stage, and subsequent
stages are numbered in succession. It is usually desirable to connect a small condenser to the discharge of each
diffuser primarily for the purpose of reducing all condensable gases to the liquid state, thus imposing on subsequent
stages the work of compressing only those gases which are non-condensable. The condensers so employed are known
as intercondensers. A condenser connected to the diffuser discharge of the final stage is known as an aftercondenser.
Inter- and aftercondensers may be either direct-contact (barometric) or shell & tube (surface) condensers.
A single-stage ejector requires no intercondenser, but an aftercondenser may be used, if desired.
A two-stage ejector usually has an intercondenser between stages, and an aftercondenser may be employed, if desired.
Where the capacity required is small, or the steam consumption is not important, or where space limitations will not
permit installing an intercondenser, a two-stage ejector may be non-condensing with the discharge of the first stage
connected to the suction of the second stage. Please see Figure 2 & 4.
A three-stage ejector, except in unusual cases, employs two intercondensers, and an aftercondenser may be used, if
desired. For unusually high vacuum and small capacity or where the temperature of the condensing water is relatively
high the intercondenser between the first and second stages of a three-stage ejector may be omitted and the discharge
of the first stage connected directly to the suction of the second stage. For very small capacities or where steam
consumption is of little importance both intercondensers may be omitted.
A four-stage ejector is used for very high vacuum. It does not have an intercondenser between the first and second
stages.
A five-stage ejector is used for extremely high vacuum. It does not have an intercondenser between the first and second
stage or between the second and third stages.
An intercondenser operates at pressures less than atmospheric; or, in other words, under vacuum. It is therefore
necessary to provide means for draining the mixture of condensing water and condensed steam from a direct-contact
(barometric) intercondenser, or the condensed steam only from a shell & tube (surface) intercondenser.
An aftercondenser operates at atmospheric pressure and is provided with a vent to allow the air and non-condensable
gases to escape. The aftercondenser does not improve the economy of an ejector and is used to recover the heat of the
steam, to recover condensate, or to condense the steam from the final stage in order to prevent its being a nuisance.
SECTION 2
SHIPPING, RECEIVING INSPECTION AND STORAGE
SHIPPING INFORMATION
The ejector system was prepared for delivery (typically via flatbed truck) at the factory. It was hydrotested for leaks and
inspected in accordance with Unique Systems QC procedures (certificate is attached to this document, and sent with the
shipping documentation). Digital photos are taken of the equipment before and after loading on the truck for record
purposes. The unit(s) were drained thoroughly and all drain connections plugged. All openings were covered, and
flange faces were coated with a corrosion inhibitor. A copy of this manual was also sent attached to the skid (usually on
a CD-ROM). Please read carefully the instructions that follow relative to inspection and recording of any shipping
damage. Every shipment for which Unique Systems is responsible (FOB,CIF, etc jobsite) will be fully insured for the
replacement value of the equipment.
All valves are shipped in the OPEN position. All electrical panels or valve actuators were shipped sealed and locked.
Please note the instruction below, and in the actuator manuals (attached) instructions regarding energizing of space
heaters for moisture control.
Some components on the system may have been partially disassembled and attached to the skid. Appropriate matchmarks are made to facilitate re-assembly on site. A drawing showing final assembly configuration has also been
attached to the skid. A number of components (such as drain traps, gauges, etc) are commonly shipped loose for field
installation.
A spray can of each paint used on the equipment is also included for touch-up of minor paint damage that may occur
during shipping and unloading.
RECEIVING INSPECTION
Immediately on receipt of the equipment, BEFORE UNLOADING, a careful inspection of the equipment must be done to
note and record any shipping damage. A Unique Systems SHIPPING AND RECEIVING INSPECTION REPORT form
is attached to the equipment, and a copy is also included with the shipping paperwork. This form MUST be completed
and returned to Unique Systems if any claim is to be made for shipping damage. It is also required that digital
photographs be taken of any damage, and sent with the Inspection Report Form. We strongly recommend that photos
be taken of the equipment both before and after unloading for record purposes, even if no damage is noted. The Bill of
Lading must be signed by an authorized person at the site, and a copy sent to Unique Systems with any damage claim.
*****NOTICE*****NOTICE*****NOTICE*****NOTICE*****
Notice is hereby given that any claim for shipping damage made to Unique Systems will be
rejected unless the SHIPPING AND RECEIVING INSPECTION REPORT FORM , a signed Bill of
Lading noting damage, and supporting digital photographs are sent to Unique Systems
within one week of the delivery date to the jobsite.
Carefully check all packaging, crates, and boxes for parts and documentation before discarding for disposal.
Documentation may be attached directly on the skid, or in some cases placed in a waterproof container or box strapped
to the skid. If an electrical panel is part of the scope of supply, electrical drawings and documentation will be placed
inside the panel.
Any BOM items on the shipping documentation that are missing must be noted on the signed Bill of Lading and
receiving inspection form and transmitted to Unique Systems within one (1) week of delivery. Digital photographs of the
equipment PRIOR TO UNLOADING, and after unloading, must be submitted with any claim. Unique Systems will
maintain complete records and photographs of exactly what was included with each shipment.
While documentation attached to the skid may not be complete, comprehensive, or even the final or latest revision, it is
extremely important that all such documentation be collected and secured in a safe location. This manual MUST be
read by all on-site personnel that will be involved with the installation and start-up of the equipment.
STORAGE
The equipment has been prepared for on-site storage for up to six (6) months, PROVIDED that the following instructions
are followed.
It is highly recommended that the instructions given below under CLEANING AND TOUCH-UP be followed and
performed BEFORE placing the equipment into on-site storage.
All opening and connection points have been covered and flange surfaces coated with rust inhibitor. DO NOT remove
covers unless there is reason to suspect damage or some other major problem. If any covers are removed, they must
be replaced, in like fashion, prior to placing the equipment in storage.
For short-term storage (up to 6 months), equipment should be stored indoors whenever possible. It should be covered
with a tarp and placed in an area where frequent moving and handling will not be required. If outdoor storage is the only
option, the equipment must be covered with a waterproof tarp. The skid must be elevated at least 6 above the ground
to allow for air circulation underneath. It must be protected from flooding, high winds, or direct sunlight.
Careful attention must be given to electrical components (if any). In particular, motor actuators will have internal space
heaters that MUST be energized at all times during storage. FAILURE TO COMPLY WITH THIS REQUIREMENT WILL
VOID ANY PRODUCT WARRANTY FROM THE MANUFACTURER OR UNIQUE SYSTEMS. Instructions for required
power supply and connection to the actuators is given in the attached Actuator documentation. Under no circumstances
should actuator housings be removed and left off the actuator. ALWAYS replace the housing covers and secure
according the instruction manual for that item. Some skid mounted control panels and junction boxes also contain space
heaters for condensation control. If so, this will be noted on the panel face, and these items must also be energized for
the duration of the storage. Instructions for electrical hook-up are noted on the drawing inside the panel. The panel face
(door) must be secured and locked after connections are made.
All valves are shipped in the OPEN position, and should be left in this position during storage. For some valves, a
manual open/close schedule may be required to prevent binding and seat decay. This will be noted in the Special
Instructions section (SECTION 12) of this manual if applicable.
The equipment MUST be inspected at least once each month. An ON-SITE STORAGE INSPECTION LOG report form
included with this manual is provided for use in recording these monthly inspections. Any damage, paint failures, or
other signs of trouble must be recorded on this form. Note that any claim for warranty repair or service during or after
storage must be supported by transmittal of this log sheet to Unique Systems, which includes the date the damage was
first noticed and the extent of the problem. Digital photographs must be taken to support any claim. Note that minor
problems with rust, dirt, etc. are NOT considered a valid warranty item, as these can usually be prevented and/or
corrected by the customer during storage or installation.
For long-term storage (durations longer than 6 months), INDOOR STORAGE IS MANDATORY, unless special
provisions have been made part of the order for securing and protecting the equipment for extended outdoor storage.
Whenever possible, the equipment should be stored in the same container or crate it was delivered in. Additional
required protective measures (if any) will be noted under the Special Instructions section of this manual (SECTION 12).
Failure to follow these instructions, with supporting inspection report logs and digital photographs, will void any warranty
by component manufacturers and Unique Systems.
CLEANING AND TOUCH-UP

It is common that equipment will arrive at the jobsite dirty, with dust, mud, etc. from the road trip. If the equipment will
be put into long-term storage, it must be cleaned prior to securing for storage, using a water spray and mild soap
detergent to remove road debris. The unit should be carefully inspected (see above) for any signs of rust or paint
failure, and these areas must be touched-up immediately. Instructions for minor touch-up are given under the Special
Instructions (SECTION 12) in this manual. Touch-up paint for each color and paint type is included on the skid for this
purpose.
DO NOT REMOVE RUST INHIBITOR COATINGS ON MACHINED SURFACES OR FLANGE FACES PRIOR TO
INSTALLATION!! If these coatings appear to be partially removed from whatever cause, they must be re-coated prior to
placing the unit in storage. Recommended coatings are given under the Special Instructions section (SECTION 12) of
this manual.
SECTION 3
INSTALLATION
FOUNDATION
The ejector system is designed to be mounted on any foundation material commonly used for heavy equipment in a
process plant, and which will provide rigid support to the full area of the load bearing members of the skid base. Details
of the foundation dimensions and anchor bolt type, size, and location are shown on the equipment General Arrangement
Drawing.
If the equipment is mounted on a concrete foundation built on solid ground, each anchor bolt should be surrounded by a
pipe sleeve 2 to 3 times the diameter of the bolt. The sleeves should be held rigidly by the concrete, yet allowing the
bolts to be moved as required to conform with the holes in the skid base. Note that Unique Systems does not normally
include anchor bolts or sleeves in the skid scope of supply. The equipment must be level and plumb in all directions.
Shims may be used at anchor bolt locations if needed, but kept to a minimum. Tighten all nuts and bolts as required,
and grout as required in accordance with common practice and local building codes.
If the unit is to be mounted directly on structural steel framing, or on another piece of equipment (such as the main
condenser shell), it should be located directly over, or as near as possible, to main structural members. If vibration
transmission from nearby equipment is possible, consideration should be given to vibration isolation pads between the
foundation and the skid support base. Lock type washers are recommended for each bolt when mounting on structural
steel foundations.
PIPING CONNECTIONS
SUCTION PIPING
Good piping system design practice dictates that suction piping between the ejector system and the condenser or vessel
must be kept as short as possible, with as few turns as possible. In no case should the diameter of the connecting
piping be less than the inlet connection diameter of the suction connection on the ejector system. Any pipe runs longer
than 100 equivalent length require special consideration, and should be checked for pressure drop, as larger diameter
pipe may be indicated. Under no circumstances should suction piping include any vertical u-bends, or loops, as this will
result in trap formation which will fill with condensate, thus severely restricting the inlet and causing serious
performance problems. If, due to space or location circumstances a trap is unavoidable, these low points must be
automatically drained using a condensate drainer. Careful design of the drain piping and drainer location is essential to
proper functioning of the drainer.
All suction piping MUST be independently supported. In no case must the allowable forces and moments on the ejector
system suction connection be allowed to exceed the value given on the equipment General Arrangement drawing, as
this may cause damage and possible misalignment of the critical nozzle-diffuser concentricity necessary for proper
functioning of the ejectors. Piping, valves, strainers, etc. in the suction piping must NOT be supported off the ejector
inlet manifold or connection nozzles of the ejector system.
COOLING WATER PIPING

Cooling water piping into and out of the condenser(s) must be of the same diameter as the condenser inlet/outlet
connections. Flange ratings on the piping connections must also be the same as on the condenser(s). All piping must
be independently supported, and forces and moments must not exceed the values listed on the F&M table on the
General Arrangement drawing.
EXHAUST (VENT) PIPING

Vent piping from the hogger ejector (if part of the system) must be discharged in a safe direction, away from other
equipment or areas where personnel may locate. It is HIGHLY RECOMMENDED that vent piping be directed vertically
through the roof whenever possible. Horizontal discharge is NOT recommended. Consideration should be given to
rainwater entering the piping system, with a rain cap if necessary. The hogger silencer includes a drain connection that
should be piped to a drain valve or automatic drainer to remove water from the silencer and piping system. All vent
piping must be independently supported, with careful design consideration given to thermal expansion criteria, and in no
case should the allowable loads on the ejector system connection exceed the value given in the F&M table on the GA
drawing. The piping must be as short and straight as possible. Total vent piping pressure drop MUST NOT exceed 1 psi
from the silencer discharge to the atmospheric outlet, based on the design flow rate of air and steam from the hogger
ejector.
UNDER NO CIRCUMSTANCES SHOULD A VALVE OR OTHER RESTRICTIVE DEVICE BE PLACED IN THE VENT
PIPING OF AN ATMOSPHERIC EJECTOR. THIS WILL CAUSE A SERIOUS SAFETY HAZARD, AS THE EJECTOR
AND SILENCER ARE NOT PRESSURE VESSELS, AND WILL BE DAMAGED IF EXCESSIVE BACKPRESSURE IS
ALLOWED TO OCCUR.
The atmospheric vent from the system aftercondenser must also be run to a safe location, preferably outdoors. A
silencer is NOT needed for this vent, as the aftercondenser itself provides adequate sound attenuation. The vent line
must NOT have any valve or restriction that can isolate the discharge from atmosphere. Piping of at least the same
diameter as the vent discharge connection on the ejector system must be used. Piping must be as short as possible,
with as few turns as possible. It must be independently supported, and in no case should the allowable loads on the
ejector system connection exceed the value given in the F&M table on the GA drawing.
STEAM PIPING
The longevity and performance of an ejector will be seriously affected by the design and installation of the steam piping
serving the unit. A poorly designed system will have a negative impact on the pressure and capacity the ejector can
produce, and may cause erosion of the nozzle and diffuser such that they must be replaced on a frequent basis. All
steam piping must be independently supported, and the loads imposed on the skid piping connection must not exceed
the value given in the F&M table of the GA drawing.
Careful consideration must be given to the steam supply piping to the ejector system, as the unit has been designed
based on a specific supply pressure and temperature at the ejector system interface connection point. Pressure drop
through the skid piping has been allowed for in the design of the ejector nozzles, but it is essential that the specified
steam conditions are available at the system connection point. Any steam ejector is a single point design as far as
motive steam conditions are concerned, and any deviation -0% or +10% beyond this specified design point may cause
improper operation of the ejectors (see below under Troubleshooting for details). In some cases, a pressure regulating
valve is included in the skid piping, and this device must be calibrated and adjusted properly to provide a constant
pressure to the ejector nozzles, per the system design specifications. If variable pressure control is provided by others, it
is essential that the regulator device be set to provide the supply pressure indicated on the design sheets.
10
If the steam supply is less than +25 F above the saturation temperature for the specified pressure (based on the design
supply conditions at the conditioning station), consideration must be given to the installation of a moisture separator and
trap. This circumstance often occurs when the ejector system is located at or near the end of a steam supply piping
system. Wet steam is a major cause of operational problems, and also causes severe damage to the internals of the
ejector.
Steam piping manifolds included with Unique Systems ejector systems include a strainer that is designed to prevent
particles large enough to cause damage or plug the nozzles from getting into the steam nozzles. The blow-down of the
strainer must be piped to a safe location.
All steam supply piping to the ejectors (including the piping manifold on the ejector skid, if any) MUST be insulated for
personnel protection, preferably after the equipment is installed on its permanent foundation. Temperatures well in
excess of 350 F are common, and will cause severe injury if accidentally touched. Insulation will also help prevent heat
loss and the formation of condensation in the steam supply to the ejector nozzles.
CONDENSATE DRAINS & TRAPS

Drain piping is, by far, the most common source of start-up and operational problems associated with ejector systems.
The inter and after condenser drain lines must be of the same size as the fitting on the unit, and NOT reduced in size or
combined together to the discharge location.
The ideal intercondenser drain configuration is a loop seal, which is essentially a trap that maintains a barometric leg
between the intercondenser and the drain collection point (most commonly the main condenser hotwell or a condensate
collection tank that operates at the same pressure as the main condenser). IC/AC Drain Trap Installation Drawing
502293 shows the required minimum dimensions required to insure proper operation of a loop seal, or a float - type
drainer configuration. Refer to the drawing section (SECTION 10) of this manual.
All drain lines must be kept as short and straight as possible. Design of the piping runs MUST allow for a minimum slope
of per foot of horizontal length. All vertical turns in the drain line should be vented back to the condenser shell, or if
no fitting is available, to a tee in the drain line located just below the condenser drain connection. Traps should also be
vented to the same location, using a minimum diameter tubing. Drain lines for loop seals should be run to a
connection BELOW the low water level in the hotwell or condensate tank. Drain lines for traps should be run to a
connection ABOVE the high water level in the hotwell or condensate tank.
Traps must be installed in the proper orientation or they will not function. This is usually noted on the trap body, and also
in the documentation for this item included in the manual (SECTION 11).
It is very important that the drain and vent lines from the inter and after condensers be kept completely
separate, and not combined or connected in any way. Cross-connected drain or vent lines will cause flooding,
short-circuiting of air, and operational problems with the ejector system.
11
SYSTEM INSTALLATION AND CHECK-OUT

Using the above general precautions as a guide, installation of the ejector system is a straight-forward process. Take
care to lift the system by the method shown on the GA drawing only. Note in particular the cautions regarding piping
connections and design. If, due to constraints of a particular installation very long runs of pipe are required for suction or
vent piping, or if many twists and turns are required, Unique Systems should be consulted prior to fabrication or
installation of piping connections. Excessive pressure drop will result in overall condenser-vacuum system performance
that will not meet expectations. The same care should be used in drain piping design (see above).
When installing the unit on the foundation and before connecting piping, all flange faces must be cleaned of rust inhibitor.
Use a solvent as recommended by the inhibitor manufacturer (see SECTION 12). Carefully check flange faces for any
damage, including nicks, scratches, etc. Use of the proper gasket material is critical to obtaining a proper seal. For
most flange connections, non-asbestos impregnated fiber type gaskets (BG-3000, for example) is adequate. In some
cases, such as for high pressure cooling water connections, a recessed or o-ring type gasket may be required. When
applicable, this will be noted on the GA drawing.
For flanged connections in the motive steam line, a graphite impregnated gasket is recommended. Certain connections
will require flexitalic gaskets (metal bound), which will be noted on the BOM.
It is of vital importance that all piping systems connected to the ejector system be thoroughly cleaned prior to final
assembly. Although ejector systems are not nearly as susceptible to debris damage as rotating machinery, some
components, such as resilient seated valves, can be damaged by metallic debris. Fine particulates will cause problems
by clogging nozzles, strainers, and drain trap orifices.
MECHANICAL
The installed system should be checked for mechanical operation of all valves. All bolts should be tightened to the
recommended torque. NEW GASKETS ONLY should be used on all flanged connections, if for any reason a flanged
connection is broken during installation (or any other time).
All strainers should be inspected and cleaned, if necessary, before start-up. If large quantities of particulates are found
in the system, it should be flushed thoroughly before start-up, as this debris will cause problems during the start-up
process if left in the system.
Before installing insulation on steam piping (or any other system component), be sure to carefully inspect the condition of
the paint on all surfaces. Field touch-up should be done where necessary to remove any rust or areas where the paint
has been damaged during the installation work.
BE CERTAIN that all safety relief valves are piped in accordance with applicable codes, and that all vents are located so
as prevent accidental injury in the event the valve(s) open. Each relief valve should be opened using the manual lift
lever to insure it is not stuck in the closed position prior to start-up.
There are three different pressure design zones on a typical ejector system: the steam piping, the tube side of the
inter/after condensers, and the shell side or process side of the system. Each was hydrotested at the factory in
accordance with applicable codes and quality control procedures (hydrotest certificates are included under SECTION 15,
and with a QC document package submitted after shipment to the customer). If for any reason the factory installed
piping or component must be removed at the jobsite, the client must determine, based on local codes and insurance
regulations, whether the unit should be re-hydrotested. Hydrotest pressures are indicted on the GA drawing.
Contact Unique Systems if any assistance is required.
12
ELECTRICAL
If electrical components are included on the system, they will have been tested at the factory for proper operation and
wiring. However, it is not uncommon for wire connections to loosen during shipping and installation, and a qualified
electrician should thoroughly inspect all connections for tightness. Proper wiring is, of course, essential to correct
functioning of the device, and an electrical continuity check should be made for all connections. When wiring is
complete and power is available, each actuator should be operated across the entire range to insure proper operation
and setting of limit and torque switches (see Actuator Instruction Manuals in SECTION 11). For pneumatic actuators,
the solenoid valve connections should be checked for proper wiring, and the pneumatic regulator should be set for
delivering the correct air pressure. Limit switches should be adjusted as required.
For skid mounted electrical panels or junction boxes, be sure to check the setting on any space heaters, timers, safety
switches, etc. prior to start-up. A continuity check of all connections from the panel to the plant DCS should be done
prior to operating the valves (or other device) electrically. All panel doors must be fully closed and locked prior to startup.
13
SECTION 4
OPERATION
TYPICAL AIR REMOVAL SYSTEM START-UP
Starting up a new plant for the first time (really every time!) is a challenging process. Many pieces of equipment must
be brought up to operating condition simultaneously, some of which (such as steam turbines) require a lot of adjustment.
During the break-in or initial start-up period for a new plant, it is very common that there are many air leaks in the
system that must be found and fixed before much progress can be made. Volumes have been written on this subject,
and it is emphasized that EVERY POSSIBLE source of air leakage must be found and fixed. Additional information on
leakage testing is given under SECTION 6.
A typical start-up process for an ejector system is as follows.
Once motive steam is available and the Turbine Gland Seal System is operating, the hogger ejector is started (manually
or remotely) by FIRST opening the motive steam isolation valve, and then slowly opening the inlet isolation valve. The
unit will begin evacuating air from the condenser and turbine. This will continue until a pressure is reached where it is
possible to introduce steam to the turbine (as determined by the turbine manufacturer), typically between 10 and 6
HgA.
The condensate (or cooling water, as applicable) pumps are started to provide water to the inter/after condenser(s).
When the pressure in the condenser reaches the pre-determined point, the SECOND ejector stage of the holding system
(mounted on the aftercondenser) is started, first by opening the steam isolation valve, and then the process isolation
valves. In some cases, it is necessary to start both first and second stages simultaneously, which is acceptable as long
as cooling water is flowing through the inter/after condenser tubes and the suction pressure is at or below 5 HgA.
When holding system operation is stable (usually within a minute or so), the hogger ejector should be shut-down.
It must be noted that the hogger ejector provides very little capacity below 6 HgA, and once steam is introduced into the
condenser, it is moving mostly water vapor, so it may as well be shut down. CAUTION is indicated if the operation of the
hogger is continued below 5 HgA, as the unit can begin to break (stop pumping), which can cause live steam to flow
back out the hogger ejector suction into the holding system and back into the condenser. This may cause damage to
resilient valve seat materials and other components. During new plant start-up it is common to operate both the hogger
and holding ejectors simultaneously (necessary due the very high leakage rate typically present), and it is recommended
that the system be monitored closely to be sure blow-back is not occurring.
With the hogger shut-down, the holding system continues to evacuate the condenser down to the pressure where the
condenser is operating on its thermal curve, based on load and circulating water temperature. It must be noted that this
is the ideal condition after air leaks have been plugged and the leakage rate to the vacuum system is below the system
capacity. If excess air leakage is present, air will tend to remain in the condenser, and the backpressure will be higher
than design.
14
When the system stabilizes at the operating point, it is recommended that the air leakage meter on the holding system
be used to take occasional readings, especially for new plants or plants that are being started after an extended outage.
This should be monitored regularly to be sure new leaks do not spring up and reduce the overall system efficiency. The
air leakage meter is not intended to be a very accurate device; it will give a relative reading on how much air is being
pumped by the system. Typical selection of these flow meters will have the system design capacity at the center of the
scale of the meter. If the meter is pegged against the top, that is a good indication that there is excessive air leakage,
and corrective action must be taken.
STEAM PRESSURE AND TEMPERATURE
As previously indicated, the quality of the motive steam supplied to the ejectors is vital to proper operation. Supply
pressure must be within -0% +10% of the specified pressure on the system data sheet, or the capacity and suction
pressure capability of the unit will be below specified requirements. Increasing the supply pressure to more than 10% of
the system rating WILL NOT increase capacity or improve performance. In fact, this will likely DECREASE capacity and
degrade system performance. This is very important for another reason: if the vacuum system is limiting the
performance of the main condenser, the backpressure will rise, which means that the condensate temperature to the
inter/after condensers will increase. If this occurs to the point where the temperature is above maximum design, the AIR
handling capacity of the system will decrease as it becomes more and more over-loaded with water vapor. This negative
spiral of events will continue until the backpressure increases to the point where the turbine will trip.
During every start-up cycle, the motive steam supply condition (pressure and temperature) must be monitored closely
until plant operation is stable. This is particularly important for cyclical operation, such as is common with Combined
Cycle plants, where the steam supply can vary considerably depending on gas turbine/HRSG operating conditions, load
to the steam turbine, etc. Steam supply temperature is also critical. If the temperature is too low, wet steam can cause
an ejector go unstable, the capacity will drop dramatically, and possibly stop pumping. If the temperature is too high, it
will result in insufficient mass flow through the nozzle (because the specific volume is increasing beyond the design
point), which will result in lower ejector capacity. Careful adjustment and monitoring of the steam conditioning system
(pressure regulation valves and desuperheating system) is essential to insuring proper ejector system performance.
SYSTEM SHUT-DOWN
Shutting down the ejector system is a straight forward procedure. Once steam supply to the turbine is stopped, the
PROCESS isolation valves on the ejector system can be closed. After a few seconds, the motive steam isolation valves
can be closed also. Vacuum in the condenser will decay gradually, or (where applicable) the vacuum breaker valves on
the condenser shell can be opened to quickly bring the unit up to atmospheric pressure. The cooling water (typically
condensate) system should remain operating until the motive steam supply to the ejectors is off.
NORMAL OPERATION CONTINUOUS & CYCLICAL

An ejector air removal system can operate on almost any operating cycle required in a power plant. This ranges from
24/7 for months of un-interrupted operation typical of a base load thermal plant, to up and down cycling several times a
day that can occur in some combined cycle units. Regardless of the nature of plant operations, a well operating ejector
system will be essential to meeting the plants heat rate requirements and on-line availability guarantees.
Once the unit as been started and the steam turbine is operating at the required load, the ejector system does not
usually require further operator attention. However, it is very important that key operational data be collected routinely
during operation. This will allow analysis of parameters such as potential component wear and maintenance scheduling,
plant performance analysis, etc. Typical data that should be collected at some regular intervals during system operation
include:
15
Pressure (vacuum) level in the condenser

Condensate temperature (in and out of the inter/after condensers)
Steam turbine load
Air leakage test data (from the skid mounted air leakage meter)
Motive Steam pressure and temperature
Main condenser cooling water supply temperature
Recommendations are given under 6 (Troubleshooting) regarding periodic checks of the ejector blank-off pressure for
evaluating the performance of both first and second stage ejectors.
All this data should be stored in a format that can be plotted and presented for analysis. It will be very useful for
evaluating plant performance and troubleshooting problems. This becomes all the more critical for cyclical operation,
common with combined cycle plants, as there are many variables that can effect plant operation from day-to-day, even
hour-to-hour.
A normally operating ejector system (in holding mode) should not exhibit any unusual noise or vibration. Since an
ejector has no moving parts, a trained Mark 1 Human Ear is the best method of detecting potential operational
problems. The operator will quickly become familiar with what normal means in this regard, and should be aware of
unusual circumstances when they develop. For example, a loud hammer noise from the ejectors, which may include a
surging noise, is indicative that one or more of the ejectors is breaking, and the process vacuum gauge may show
considerable variation in suction pressure. This indicates a potential major problem that must be investigated (see
Troubleshooting). Water droplets or even a flow of water out of the vent is indicative of a flooded aftercondenser,
suggesting that the drain trap is not functioning, etc.
On some units there is an isolation valve on the discharge of each first stage ejector (the Y stage, connected to the
process, as opposed to the second stage, which discharges to atmosphere through the aftercondenser). This item is
NOT used during normal operation. It is intended only for removal of one first stage ejector for maintenance while
allowing operation of the system with the stand-by ejector. Closing this valve will result in the popping open of the
safety relief valve on the first stage ejector body when the motive steam is turned on. While not a hazard from the
standpoint of safety, it obviously is not normal operation, and serves no operational purpose, but only wastes steam.
16
SECTION 5
ROUTINE MAINTENANCE
One of the main reasons ejectors are used routinely in power plants is that they are so simple and reliable. It is not
uncommon for an ejector system to operate for many years with literally no maintenance. While it happens, it is by no
means recommended that the old saw if it aint broke, dont fix it should govern a piece of process equipment, no
matter how reliable it may be. Proper, regular attention to the ejector system will help insure that it remains reliable, and
performs at peak efficiency.
The following is offered as a guide only as to what should normally be checked on a regular basis. Regular means
whatever is determined for a given plant, usually based on scheduled outages for a week or more. Ejector system
checks and routine maintenance can usually be accomplished in these periods, unless a major problem develops
(fortunately this is very rare) that would cause a complete system outage.
SYSTEM COMPONENT CHECKS
Ejectors should be physically inspected at least yearly to check on the condition of the critical internal geometry, in
particular the nozzle throat and the diffuser throat. Most Unique Systems ejectors incorporate our patented QuickCheck
steam chest that makes this task very simple. Instructions for the gage rod are given in the QuickCheck brochure in
SECTION 12 (Special Instructions). If there is any reason to suspect the ejectors have been exposed to wet steam, or
have not been visually inspected for a number of years, they should be removed and the condition of the nozzle exit
taper and diffuser inlet taper be examined for signs of pitting, wire drawing, severe erosion, etc. Any components
showing this type of wear should be replaced. Be sure to use new gaskets when re-assembling an ejector.
Inter/after condensers will normally not need any type of routine maintenance. The condition of the tubes should be
checked after the first 5 years of operation by visual inspection. New gaskets should always be used whenever a piping
connection is removed. If a tube should spring a leak, common practice is to insert a plug in both ends of that tube.
This can normally be done without significantly effecting system performance, but it is not recommended that more than
5% of the total number of tubes be plugged. Should this circumstance develop, an investigation should be made as to
the cause of excessive tube failure, and these tubes should be replaced. Consideration may need to be given to
replacing the entire tube bundle if a significant number of tubes have failed, as this is not a common occurrence.
Cleaning of the condenser tubes is normally done using chemical methods. Mechanical cleaning is not normally
required, as this application is one of the cleanest, with treated condensate as the fluid on both sides of the tubes.
Mechanical cleaning is indicated only if sever scaling is present.
Valves do not normally require routine maintenance. Any leaks should be investigated, and the packing or seats
tightened or replaced as required. The condition of resilient seated valves, such as butterfly or ball type, should be
checked annually for signs of hardening, cracking, or flaking due to excess temperature or chemical attack. If there is
any reason to suspect the condition of a valve seat, it should be replaced.
17
Valve Actuators on systems which have pneumatics or motors should be checked annually. Catalog cuts and
maintenance instructions for the devices on this specific system are included in this manual in SECTION 11 with any
special requirements given in SECTION 12. Each actuator should be cycled several times through open/close, and the
function of electrical components such as limit switches and solenoid valves checked.
Instrumentation should be checked annually for calibration. Many plants have set up calibration centers in the
maintenance shop for pressure and temperature gauges, or have this done by local contractors. This is very important,
as the veracity of the data collected during operation depends on the accuracy of the instrumentation used to collect the
information. Any gauge which does not calibrate reliably, or which consistently gives readings that vary significantly from
other instrumentation in the same process should be replaced.
Transmitters which send a 4-20ma signal to the control system should also be calibrated at least annually. Most such
units today are of the smart type, with modular circuits that allow easy on-line calibration or replacement of component
boards that will not deliver a consistent, repeatable signal. The accuracy of the data collected is critical to proper
operation and plant evaluation, so any component which does not provide reliable operation must be replaced.
The air flow meter on the ejector system vent is not intended to be a highly accurate device. It will give an indication of
the relative amount of air that the ejector system is pumping out of the condenser, which is indicative of the amount of air
leaking into the condenser. This device does not require routine maintenance, but should be checked for damage
annually. Excessive amounts of liquid water in the form of droplets can damage the unit. Internals of this item are not
considered replaceable, and if indicated, the entire meter should be replaced.
Any special instrumentation that may be installed for a specific system will have catalog and maintenance instructions
included in SECTIONS 11 and 12 of this manual.
REPLACEMENT PARTS
Replacement parts for any component included with the original scope of supply can be obtained directly from the
system supplier. Information needed to identify any component is as follows:
System Serial Number (listed in the Forward to this manual, and on numerous drawings and data sheets)
Part Number or Item Number as listed on the General Arrangement Drawing or Ejector BOM.
In addition, a Recommended Spare Parts List is included in this manual under SECTION 8. This list contains items that
normally require replacement on average every 5 years of operation, although this can vary considerably from plant to
plant. Normal delivery times are given to aid in planning what specific items should be kept in stock on-site.
QUICKCHECK NOZZLES
The Unique Systems patented QuickCheck nozzle system allows an operator to check on the condition of the critical
nozzle and diffuser throat diameters in as little as 15 minutes, without disassembling or removing the ejectors or steam
piping. This feature includes a Performance Gage RodSM that is a go/no-go dimensional check. If the rod passes
through the nozzle or the diffuser throat, it is time to replace that component as it has worn past the maximum allowable
dimensional tolerance. Operation of the ejectors at this point is marginal, and it is reasonable to expect that the
capacity and vacuum range of the ejectors has diminished at least 10+% from the original new unit design.
Replacement of the nozzle is quick and easy, as it can be removed without further disassembly of the unit. Replacement
of the diffuser will require removing the ejector from the system.
Note the QuickCheck feature is not standard on ejectors larger than 6 in inlet diameter, and it may not be included on
every ejector that is part of the system.
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SECTION 6
TROUBLESHOOTING AND TESTING
IS IT THE EJECTOR SYSTEM?
It is quite normal, when there is an apparent problem with maintaining the required vacuum level in the condenser, to
immediately look at the ejector system and assume that the cause of the problem is there. However, without a well
thought out plan to troubleshoot the problem in a logical, systematic manner, the operator will spend a lot of time going
in circles without finding the root cause of the problem. Inadequate vacuum levels can be caused by a number of things
that have nothing to do the ejector system, and these must be investigated first. Fortunately, the checks for these
causes are relatively simple and straightforward.
If an ejector system is operating as designed, it is removing all the air that leaks into the condenser and the condenser is
operating on its design curve as a function of steam load and cooling water temperature. It is very common, especially
with Combined Cycle plants, that steam loads to the condenser can vary considerably depending on the gas turbine
operating condition, how many CTs are operating, etc. Seasonal and even hourly changes in load can cause wide
swings in condenser backpressure at any given time. Before suspecting the vacuum system, the condenser curves
should be examined to determine what the actual backpressure should be as function of load and cooling water
temperature. In some cases, particularly in colder months, the backpressure may try to drop lower than the minimum
design capability of the ejector system (in low partial load cases with cold cooling water). In these cases, the ejector
system may indeed by limiting in terms of available capacity, but there is no operational problem with the unit.
Check the Ejector System Data Sheet in SECTION 9 for confirmation of the operational design parameters of your
particular system.
A common cause of inadequate vacuum in the condenser is excessive air leaks. If the air in-leakage rate exceeds the
design capacity of the ejector system, air will tend to accumulate in the steam space of the condenser, which acts to
insulate the tubes and reduces the efficiency of the heat transfer process. The result is that for a given load and cooling
water temperature, the condenser will operate at a higher absolute pressure than indicated on the performance curve.
This is NOT due to a problem in the ejector system, but rather in the condenser and/or associated piping system. If the
steam turbine gland seals are worn, or the gland steam vacuum system is not functioning properly, excess air will get
into the condenser from the turbine. This obvious source of air leaks should be checked if the air flow meter on the
ejector system indicates excess leakage. Additional information on checking for air leakage is given below.
If all the above has been checked and inadequate vacuum is still a problem, attention should be focused on the ejector
system. As indicted, a logical, systematic troubleshooting schedule should be followed based on the indicated problem
and the most common causes.
19
EJECTOR PROBLEMS SYMPTOMS & CORRECTIIVE METHODS

The most common problem with an ejector system is basically described as inadequate vacuum, meaning that the
pressure level in the condenser is too high, based on where the condenser curve indicates the unit should be operating
for a given load and cooling water temperature. If the most common cause is indicated excessive air leakage
proceed to item 4 below for suggested methods of correction.
There are a number of parameters that can cause improper functioning of an ejector system, and each is addressed as
follows.
1. SYMPTOM: POOR VACUUM (UNSTABLE OPERATION) - MOTIVE STEAM CONDITIONS
Every steam ejector is designed for a very specific motive steam supply condition (pressure and temperature),
and is actually quite sensitive to any changes in the supply conditions. Critical Flow ejectors typically those
designed to discharge to atmospheric pressure, are very sensitive, as are ejectors operating at very low absolute
pressures (not common on condenser air removal systems). IT IS ESSENTIAL THAT THE DESIGN MOTIVE
STEAM PRESSURE AND TEMPERATURE BE MAINTAINED AT THE SYSTEM INTERFACE CONNECTION
POINT FOR PROPER EJECTOR OPERATION.
For the most reliable operation, Unique Systems recommends that the motive steam pressure supply to the
ejector system be maintained with a MAXIMUM tolerance of -0% to +10% of the design pressure listed on the
system data sheets. The motive pressure is also stamped on the ejector nameplates. Note, however, that the
stamped pressure is typically several psi BELOW the system design pressure, as the nameplate rating allows
for a calculated pressure drop across the system manifold piping, valves, strainers, etc. It is important that the
operator maintain the pressure listed on the system data sheet.
a) LOW MOTIVE PRESSURE - If the motive pressure is allowed to drop below the design point, ejector
operation may start to go unstable, characterized by fluctuating vacuum gauge readings, and possibly a
hammer or surging noise from the ejectors. Even if they are not breaking, the capacity is dropping rapidly,
and will reach a point where the ejectors will definitely break and stop pumping. When this occurs, all you have
is steam blowing through a pipe, with no compression of the inlet gases. The system capacity is in effect zero
when this occurs.
Solution Increase motive supply pressure to at least the system design pressure listed on the data sheets.
b) HIGH MOTIVE PRESSURE - If the motive pressure is increased beyond 10% of the design point, no actual
benefit is obtained in terms of added capacity or compression range. Since the diffuser diameter is fixed,
increasing motive pressure will result in more steam flow through the nozzle, which at some point will choke the
diffuser, causing a decrease in inlet capacity. If pressure is increased beyond 20% of design, it is likely that the
unit will break (stop pumping), as the diffuser is choked with too much mass flow, and steam can start to backflow out of the suction connection.
Solution Decrease motive supply pressure to within +10% of the design pressure listed on the system data
sheet.
20
c) HIGH MOTIVE TEMPERATURE - Motive steam temperature is also critical to ejector performance. The
steam nozzle and diffuser geometry design is a function of the specific volume of the mass flow, which is a
function of temperature at any given pressure. If the temperature of the steam is too high above design,
insufficient mass flow will pass through the nozzle which will reduce the inlet capacity of the ejector.
Solution Adjust the steam conditioning system to maintain the motive supply temperature to within +50 F of
the design temperature listed on the system data sheet.
d) LOW MOTIVE TEMPERATURE (WET STEAM) Caused by the presence of water droplets in the motive
supply due to the temperature dropping below the saturation point at a given pressure, is a common and serious
problem. Symptoms of wet steam include fluctuating vacuum gauge readings and fluctuating steam pressure
gauge readings, which will coincide. Not only does wet steam seriously effect ejector performance, it will also
cause major damage to the critical internal geometry of the ejectors, and greatly decrease unit longevity.
Solution Adjust the steam conditioning valve to maintain a minimum 25 F above the saturation temperature at
the supply pressure. On systems where Dry & Saturated steam is the design point, check traps and separators
in the steam supply to the ejector system for proper operation. It may be necessary to install a separator and
trap if they are not in the piping system. They should be located as close to the ejector system as practical. Be
sure motive steam lines are insulated.
2. SYMPTOM: POOR VACUUM - MECHANICAL CONDITION OF EJECTOR COMPONENTS

If steam conditions are set correctly but poor vacuum still persists, the next step is to check the condition of the
ejector itself. Before removing the ejector and doing major disassembly work, the nozzle should be removed
and checked for solids plugging the throat. For ejectors with the QuickCheck steam chest (documentation in
SECTION 12, if applicable), this is a matter of a few minutes time. It is common in new plant start-ups for debris
to get into the steam system, and a partially blocked nozzle is a common cause of poor ejector performance.
Testing an ejector for performance can be a difficult and time consuming task, and requires special equipment
(calibrated orifices, accurate instrumentation, test headers, etc.) which makes it unlikely to be a routine option
for most operators. However, there is a simple test called the Blank-Off check that is easy to perform and will
give a good indication of the relative ejector performance when compared to the curve.
BLANK-OFF TESTING is done one stage at a time. The performance of the second stage ejector is very
critical to overall system performance. If this ejector is not functioning as required, the first stage ejector will also
not work properly, since its performance is dependent upon the second stage performance.
A blank-off test should be done while the unit is in operation on the condenser. First make sure that the motive
steam supply is within specified tolerance. A pressure gauge should be fitted to one of the plugged connections
on the ejector suction chamber (if one is not available on the intercondenser shell). Shut down the motive steam
supply to the FIRST STAGE EJECTOR ONLY, and then close the inlet isolation valve to the first stage ejector.
DO NOT CLOSE THE DISCHARGE VALVE ON THE FIRST STAGE EJECTOR!!

After a few seconds, record the suction pressure at the second stage inlet. Then, open the first stage inlet and
steam valve (in that order). Next, leaving everything else operating as is, close the inlet isolation valve again and
take a reading of the suction pressure on the first stage ejector suction, using a gauge attached one of the spare
fittings on the 1st stage body.
21
This should be repeated at least twice to be sure of the accuracy of the data. Repeat several times as required
to obtain consistent readings. Condenser vacuum levels may fluctuate somewhat (depending on the actual air
leakage rate), but the brief time required to do the test should not cause vacuum to rise enough to cause a
turbine trip.
Compare the suction pressure readings obtained from the test of the second stage ejector with the blank-off
pressure shown on the performance curves (where the curve crosses the Y axis). If the blank off reading
obtained is more than 0.5 HgA higher than the curve value (meaning blank-off is higher in absolute pressure),
there is reason to suspect that the ejector is not performing as designed. If the second stage is not blanking-off
where required, it is unlikely that the first stage will either. If the second stage is within tolerance, but the first
stage is not, then the first stage may require attention.
If the blank-off tests do not fall within tolerance, there is reason to suspect that the ejector nozzle and/or diffuser
is worn beyond acceptable limits, has been damaged by wet steam, or has corroded to the point where
dimensional tolerances have been exceeded. Removal and inspection of the ejectors is indicated.
If the blank-off tests show that the ejectors ARE within performance tolerance, the problem of poor vacuum is not
likely due to the condition of the steam ejectors.
EJECTOR STAGE INSPECTION
The condition of the steam nozzle and diffuser is important to proper ejector performance. Excessively worn
diameters, wire-drawing in the nozzle and diffuser tapers, pitting, and corrosion are all indicative of problems
that must be corrected. While ejectors generally give long, trouble-free service, the will eventually erode,
particularly if operated with wet steam. Inspection should focus on the following areas:
DIFFUSERS Check for build up on the inside surfaces of the diffuser, and clean with a scraper and abrasive
cloth. If there are signs of MINOR pitting and grooving, these should be smoothed and blended to give a
uniform and clean surface, TAKING CARE TO AVOID REMOVING METAL AS FAR AS POSSIBLE. After
cleaning, measurements should be taken of the diameter of the straight section of the diffuser (called the throat)
at several locations along the length and in several radial planes. If there is significant out of roundness or
taper along the length, or if pitting and grooving cannot be removed without excessive removal of metal, the
diffuser must be replaced.
In theory, any increase in the diffuser throat diameter will cause a failure of that stage. In practice, however,
units are designed with some margin, and an increase of 1 - 3% of the original diameter should not cause a
significant problem. If measured wear is greater than this, and a replacement is not readily available, operation
of the stage may be temporarily restored by increasing steam pressure (no more than 10% above design). If this
does not work, the unit must be replaced.
NOZZLES also wear and corrode, but usually not to the extent of diffusers, which is to some degree due to
industry standard practice of using stainless steel for this component. Check the throat and outlet taper for
grooving and out of round dimensions as indicated above. Clean and polish if possible, taking care NOT to
remove any metal. The throat CANNOT be re-bored or increased in diameter, as this will increase the motive
steam flow which can negatively impact condenser performance. If the nozzle throat is worn beyond 2% of the
diameter, the nozzle should be replaced.
22
INSPECTION OF CONDENSERS Involves visually inspecting the condition of the tube ends and surfaces (using
the inlet nozzles once the ejector stages have been removed). Fiber optic devices are sometimes used for this
purpose if a broken tube is suspected. If the tubes show significant signs of scale build-up, they should be
cleaned either chemically or mechanically. Check the bottom of the condenser shell for build-up of debris, and
clean and flush as necessary.
3. SYMPTOM: POOR VACUUM - IMPROPER DRAINAGE
A common problem with new systems is flooding of the inter and after condensers. This is caused by several
factors, the most common being clogged trap orifices, improper installation of the traps, improper venting of traps
and horizontal pipe runs, and cross connecting the inter and after condenser drain lines.
Flooding of the condenser is usually indicated by poor vacuum levels combined with significant amounts of water
droplets (sometimes even steady streams of water) coming out the aftercondenser air vent line from the air flow
meter. If this is observed, the aftercondenser drain must be checked immediately. The trap should be
disconnected from the AC drain and the condensate allowed to flow out onto the floor. If large amounts of water
are observed, it is a good indication of problems with the trap installation or clogging of the trap with debris
(common during new plant start-up). With the aftercondenser draining onto the floor the performance of the
ejector system should begin to stabilize.
SOLUTION Check the trap for clogged orifice, clean as required. Check the location of the trap against the
General Arrangement drawing to be sure adequate vertical distance is allowed from the condenser drain
connection. Check to be sure vent lines have been installed per the drawing, and that long horizontal runs have
been vented. Check to make sure the AC drain line has NOT been connected to the intercondenser drain lines.
Check to make sure that the IC and AC vent lines have NOT been cross connected, and are vented to the
proper condenser shell. Check to make sure that the drain lines are piped to the proper level in the main
condenser hotwell or condensate collection tank. Note that the AC drain can be piped above the condenser
hotwell water level, but the IC drain line must be at least 6 below the minimum hotwell water level.
Flooding of the intercondenser can be caused the same conditions, especially clogged trap orifices (where traps
are used), or improper venting of the line where drain loops or traps are used.
SOLUTION Check the trap for debris and clean as required. Check vent lines and make sure any long
horizontal runs are properly vented. Check for cross connection of drain or vent lines with the aftercondenser
drains. Check to make sure the IC drain is piped below the minimum hotwell water level. Check that all
horizontal pipe runs are adequately sloped (minimum per linear foot). Check to make sure the same pipe
diameter is used from the intercondenser drain outlet (in no case should the pipe be reduced in diameter
between the IC drain connection and the hotwell connection.
4. SYMPTOM: POOR VACUUM - EXCESS AIR LEAKAGE & TESTING
The most common cause of poor vacuum in new plant start-up is excess air leakage. This condition can
develop (and worsen) as the plant ages. Air can leak into the condenser from many sources, including the
turbine (poor seals or improper operation of the gland steam system), loose flanges, worn and cracked
expansion joints, valve packing, etc. Finding and fixing leaks is an on-going maintenance task that never really
ends. It is absolutely essential that the leakage of air into the condenser be kept as low as possible. In
any case, it cannot be allowed to exceed the design capacity of the ejector system.
23
Each Unique Systems Ejector Air Removal System includes an air leakage meter on the vent of the
aftercondenser that will allow the operator to quickly and easily measure the approximate air leakage being
pumped by the vacuum system. The meter is selected such that the specified capacity of the system is at the
center of the meter scale. The leakage rate can be measured whenever the holding system is operating in
stable condition. This should be checked at regular intervals during normal plant operation.
When excess leakage exists, it magnitude is usually such that the meter will be pegged against the top of the
scale. If this is observed, the operator has no other alternative than to find and fix the leak(s). No other
troubleshooting is indicated, as until the leaks are fixed the main condenser will never be able to perform along
the design curve. Backpressure on the turbine will always exceed the required value. Troubleshooting other
potential system problems will be of little value unless/until the leaks are fixed.
SOLUTION Find and fix the leaks!!
Finding leaks is a straight forward process, but by no means easy or simple. It is recommended that the
operator consider the services of companies that specialize in this area. They will likely use a Helium or
Ultrasonic leak detector to find any significant leaks. This testing is done while the vacuum system is operating.
Leakage sources are detected and localized for correction when the plant is down. This process must continue
until the measured leakage rate is below the design capacity of the vacuum system. It should be noted that
even very small holes can be a major source of air leakage. A hole as small as diameter (either by itself or
as a collection of even smaller holes) in a turbine/condenser system can result in too much air for the ejector
system to handle, based on typical capacities required for air removal duty in current plant designs.
One way to determine if excess leakage is present is to do a Vacuum Drop Test. To do this, evacuate the
condenser using the hogger ejector to around 6 HgA. The turbine gland seal system must be operating, but the
steam turbine does not need to be running. When this level is reached, close off the hogger suction and steam
isolation valve, and start timing the rise in pressure between 1 HgA intervals until the pressure increases to
around 12 HgA. The following formula is used to determine the leakage rate into the system:
Leakage (#/hr) = 0.15 x V x PR

T
Where V = System Volume (including the turbine)
PR = Pressure Rise (Inches Hg)
T = Time for PR (minutes)
If the calculated leakage is near or above the specified DRY AIR handling capacity of the vacuum system,
corrective action must be taken.
5. SYMPTOM:
IMPROPER OPERATION OR COMPONENT FAILURE
While ejector systems are relatively simple units with no moving parts (other than occasional valve actuation),
some components require periodic inspection and maintenance.
24
SOLUTION:
VALVES - Should be inspected during scheduled maintenance outages. Valves with stem packing (gate, globe,
etc.) should be checked for any sign of leakage, and the packing gland tightened or, in cases where the leakage
cannot be stopped by reasonable tightening of the gland, the packing should be replaced. For resilient seated
valves (butterfly, ball, etc.) the condition of the seat material should be checked for signs of hardening or
cracking. In many cases this is not possible without disassembly of some components or piping, but if leaks or
obvious indications of a problem exist, the valve seat material should be inspected.
ACTUATORS Require scheduled maintenance and periodic adjustment. Please read the manufacturers
recommended maintenance included with this manual.
INSTRUMENTATION Should be inspected in accordance with the manufacturers instructions per the
information included with this manual. Periodic calibration is required for some devices, particularly electronic
transmitters.
AIR FLOW METER Should be checked during scheduled outages for signs of damage that may be caused by
water droplets. The indicator paddle should move freely, and the orifice should be open and cleaned of any
debris.
TRAPS Should be checked during scheduled outages for debris and cleaned as required. It is recommended
that new gaskets be used when re-assembling the unit. The orifice seat should be examined for signs of pitting
or chipping caused by debris and replaced if there is any indication of damage.
6. SYMPTOM:
ERRATIC HOGGER PERFORMANCE
Operation of the hogger ejector is simple and straightforward. If the performance of the ejector is erratic,
evidenced by fluctuating steam or vacuum readings, or if unusual noise develops during operation, it is usually
indicative of either motive steam pressure or temperature supply outside of design tolerances, or excessive
backpressure has developed.
SOLUTION check the motive steam supply to be sure it is set at the design point (see item 1 above). If
possible, increase the motive steam pressure to 10 psig above the design pressure and see if this corrects the
problem. Critical flow ejectors are very sensitive to motive steam pressure, and especially to wet steam. Motive
pressure below the design point, or wet steam, will likely cause unstable operation of a hogger. If the problem
persists, the nozzle should be checked per item 2 above.
Operation of a hogger at or near blank-off pressure may also cause instability, which can result in steam flowing
out the inlet nozzle into the process lines back to the condenser. This can damage resilient valve seats and
should be avoided. Do not attempt to operate a hogger ejector below 5 HgA suction pressure. The capacity is
very low below this level, and will be essentially zero around 4 HgA.
25
Excessive backpressure can occur when very long lengths of discharge piping are used to vent the
hogger/silencer to atmosphere, or if there are many turns in the piping. If consistent instability is observed in
hogger operation, particularly when operating below 10 HgA, the possibility of excessive backpressure should
be investigated (once the motive steam conditions are set as required). The silencer should be checked to be
sure it is not flooded or clogged with debris. The discharge piping from the silencer to atmosphere must be AT
LEAST the same diameter as the silencer discharge diameter. Piping runs longer than 50 feet (equivalent
length) should be evaluated for pressure drop. Hogger ejectors are typically designed to discharge to barometric
pressure at the site, plus 3 HgA to allow for pressure drop across the silencer and discharge piping (please see
the System Data Sheet included with this manual). There should be no valves or other means to shut-off the
hogger discharge to atmosphere. Any piping caps, bird screens, or other obstructions to flow should be
checked to be certain they are clean of any debris.
If excessive backpressure is indicated, the design of the hogger may have to be modified, unless the vent piping
can modified or re-routed. Consult with Unique Systems.
26
SECTION 7
GETTING HELP
CALLING AND ONLINE SUPPORT
Unique Systems provides phone and online support to all its customers for assistance in troubleshooting problems and
ordering parts. Before calling Unique Systems for assistance, be sure to have the following information available to help
us find the appropriate records and provide the most efficient service.
INFORMATION REQUIRED FOR TROUBLESHOOTING ASSISTANCE
System Serial Number on system or ejector body nameplate

Barometric Pressure
System Pressure (Vacuum)
Actual motive steam pressure and temperature at the system interface
Main condenser load, cooling water temperature, and backpressure (curve)
Air leakage meter reading (recent)
Condensate temperature at system connection point
Condensate temperature rise across the inter/after condenser
Status (Open/Close) of all valves on the P&ID
It is highly recommended that the customer have the system GA drawing and Ejector BOMs available.
Records of recent operational history and problems should be available, along with records of maintenance
performed in the last year.
Be sure to have a detailed description of the problem(s). If system drainage is an issue, elevation drawings
showing the drain piping routing will be very helpful. Digital photographs of the installed system, including
photos of the drain traps and piping, may be emailed to Unique Systems and will be of assistance in helping to
diagnose problems.
All valves are labeled with a tag number on the Unique Systems P&ID. Make a list of the (open/closed) status of
each valve and email or fax it to Unique for troubleshooting.
FIELD SERVICE SUPPORT

On-site field service is available from Unique Systems for installation inspection, troubleshooting assistance, operator
and maintenance training, and warranty support.
Contact Unique Systems for Field Service rates, policy, and availability of a qualified Unique Systems Field Service
Engineer.
PROCESS VACUUM EQUIPMENT

SERVICE ENGINEERING RATES & STANDARD CONDITIONS
BULLETIN # PVS-90021050-SRC
PAGE 1 OF 4
DATE:
EFFECTIVE APRIL 1, 2010
OBJECTIVE:
Unique Systems will provide qualified technical assistance and direction upon receipt
of a purchase order for the installation, inspection, repair and maintenance of
equipment located within the United States, except off-shore & Arctic site locations.
1. RATES:
DAILY RATE
STANDARD HOURLY RATE
OVERTIME (RATE "A")
OVERTIME (RATE "B")
$1,800.00
$ 225.00
$ 337.50 / Hour
$ 450.00 / Hour
These rates are subject to change without notice. Unique Systems will invoice at published rate schedule
in effect at the time services are required.
2. DAILY RATE This rate applies to time worked during a normal eight (8) hour day, Monday thru Friday,
except holidays.
3. OVERTIME (Rate "A") This rate applies to all time worked on weekdays, Monday thru Friday,
in excess of eight (8) hours per day.
4. OVERTIME (Rate "B") This rate applies to all time worked on Saturdays, Sundays and holidays.
5. TRAVEL TIME Travel time will be billed at the Standard Hourly Rate for Monday thru Friday during a
normal eight (8) hour day, Overtime (Rate "A") for time in excess of a normal eight (8) hour day and
Overtime (Rate B) for travel on Saturdays, Sundays and holidays.
6. TRAVEL & LIVING EXPENSES These expenses will be billed at cost from the time representative leaves
his home base until he returns. Economy rates for transportation and lodging will be utilized when
available. In all instances, we invite customer recommendations regarding acceptable travel and lodging
arrangements. The cost to upgrade any accommodations beyond the minimum available category will be
paid by Unique Systems or its representative. Personal vehicle mileage will be billed at the rate allowed by
the Internal Revenue Service (www.irs.gov) on the dates of travel.
7. MISCELLANEOUS EXPENSES Charges related to items such as photocopies or other reproducible media
(ie. blueprint copies, sepias, microfilm, electronic formats, etc.), reproductions from microfilm, shipping
charges for tools & testing equipment, postage, phone calls, etc., shall be added to final invoice.
8. MINIMUM BILLING Four (4) hours for time worked up to four (4) hours; eight (8) hours for time
worked in excess of four (4) hours, but less than eight (8) hours.

Value, Integrity, Professionalism & Service

PAGE 2 OF 4
9. HOME OFFICE RATE (Same as Hourly Rates) Covers all time required to assemble original design
specifications, details and Bills of Material for unit under study; all calculations, preparation of
curves and/or sketches specific to the unit and problem under study.
10. STANDBY TIME Any waiting time when the representative is available to work, up to a maximum of
eight (8) hours on any one working day, shall be regarded as time actually worked, even though services
are not actually utilized. The rate is not pro-ratable for partial days.
11. DELAYS Unique Systems shall not be liable for delay in performance when such delay is occasioned by
causes beyond its reasonable control, including but not limited to: Acts of God; acts of customer; material
shortages; transportation difficulties; flood; strikes; epidemics; war (declared or undeclared); riot; etc.
12. EMERGENCY WORK The minimum time off for a representative during any twenty-four (24) hour period
must be eight (8) consecutive hours.
13. TOOLS & TESTING EQUIPMENT Our representatives often require specialized tools and/or testing
equipment which, due to travel restrictions, must be shipped directly to a designated contact at customers
site. All such items shall remain the property of Unique Systems and customer agrees to immediately
return these items to our office upon conclusion of our representatives visit. Return shipment must be
sent via insured carrier with tracking number. Any items not returned within a reasonable period of
time will be billed at replacement cost.
14. TERMS OF PAYMENT All funds are payable in U.S. Dollars.
Domestic Accounts Payment for services and materials will be due upon presentation of monthly
invoice. Standard terms of payment are "Net 30 Days" from date of invoice, with approved credit, at
which time the entire payment shall be due absolutely, without the right of "setoff", regardless of the basis
for same. Overdue invoices will be charged 1.50% per month (18% per annum) on
outstanding balances from date of invoice.
Foreign Accounts Advance payment via wire transfer or other approved method. Adjustments should be
made to compensate for variable exchange rates and fees.
15. SALES & SIMILAR TAXES The amount of any present or future sales, use or other tax, federal, state or
local, which Unique Systems now or hereafter shall be required to pay, either on its own behalf or on the
behalf of the customer, or otherwise, with respect to the services furnished, shall (unless such prices are
expressly stated to be inclusive of such tax) be added to the prices contained above and paid by customer
in the same effect as if originally added thereto.


PAGE 3 OF 4
16. INSURANCE Unique Systems insurance policy with Excelsior Insurance Co. (Policy # CBP9764022)
applies to: All operations - manufacturing & contracting, including blanket contractual; the Netherlands
Insurance Company (Policy # BA2436045) for autos (all owned, non-owned and hired); and, Excelsior
Insurance Co. (Policy # CU9768823) for umbrella liability.
Subject to policy provisions with the following limits:
Comprehensive General Bodily injury & property damage:
$1,000,000.00 Single Occurrence / $2,000,000.00 Aggregate Limit
Automobile Liability Bodily injury & property damage:
$1,000,000.00 Single Aggregate Limit
Umbrella Liability $4,000,000 Each Occurrence / $4,000,000 Aggregate Limit to provide
additional coverage over the above liability limits.
Workmen's Compensation Policy with the New Jersey Manufacturer's Insurance Co.
(Policy # W12491-7-10).
17. RESPONSIBILITY Unique Systems agrees to indemnify, hold harmless and defend the customer from
and against any and all claims for damages, to property or for personal injuries, including death, which
result solely from the gross negligence of the representative of Unique Systems while engaged in the
services described hereunder.
Any hold harmless clause in the customer's purchase order, or in any of the customer's documents,
whether requiring the signature of a Unique Systems employee or not, shall be of no effect, and the hold
harmless clause set out herein shall apply with respect to any claims for damages, and Unique Systems
responsibility will be limited.
Accordingly:
Since it is impossible for the representative to observe and control the execution of all details of the
installation, inspection, repair and maintenance, Unique Systems will not be responsible for materials or
workmanship of others than Unique Systems, or for damages resulting from acts or omissions of others
than Unique Systems representatives.
18. APPLICABLE LAW These "Rates & Standard Conditions for Unique Systems personnel shall be the
complete agreement between the parties for such service work and shall be construed in accordance with
the Laws of the State of New Jersey, United States of America.


PAGE 4 OF 4
19. DAMAGES Unique Systems shall in no event be liable for any incidental or consequential damages
of a commercial nature, such as, but not limited to, loss of revenue, production or use of any equipment,
resulting from any cause.
20. SCHEDULE CHANGES & TRIP CANCELLATION A specific amount of time has been reserved for
customers use which has a direct impact on scheduling and time available for other projects. Our
representatives also spend time in preparation for field service work by reviewing engineering files,
drawings and other available information. We understand that there are circumstances which may result
in unexpected scheduling changes or cancellation. Unique Systems will accommodate any reasonable
requests for schedule changes to the best of our ability. Travel expenses incurred, such as airline tickets
which are non-refundable or subject to change fees, must be reimbursed by customer and may be billed
immediately. Schedule changes resulting in postponements beyond thirty (30) days from original service
date, or two (2) consecutive schedule changes, will be considered a cancellation and subject to a minimum
charge equivalent to one (1) day at the daily rate indicated above. Cancellations or postponements once
our representative has begun travel, or has already reached site, will be considered as Standby Time and
billed as one (1) day on-site plus travel time & expenses as outlined above.
21. This rate agreement covers only the following products: Steam Jet Ejector, Liquid Ring Vacuum Pump
& Hybrid Vacuum Systems, and all parts thereof, in addition to other miscellaneous vacuum products
sold by Unique Systems, Inc.
THESE SERVICE ENGINEERING RATES & STANDARD CONDITIONS MUST BE SPECIFICALLY REFERENCED &
INCORPORATED INTO ANY PURCHASE ORDER OR AGREEMENT COVERING THE WORK DESCRIBED HEREIN.
www.uniquesystems.com

SECTION 8
SPARE PARTS
Unique Systems can supply spare parts for any component of your ejector system. We recommend that the user
contact the OEM supplier of the ejector system (usually the manufacturer of the main condenser) first when securing
spare parts. This will be required if the system is under the original manufacturers product warranty.
The following information is required when ordering parts to be sure that the correct part is shipped.
System Serial Number

Part Number (from the Bill of Material on either the Ejector drawing or the GA drawing)
A description of the required part(s)
Spare parts for the individual steam ejectors are shown on the attached BOMs for each stage. A Recommended
Spares List is also attached that shows typical spares that the user should consider keeping in local stock, which is
based on average experience for this application.
BILL OF MATERIAL
ITEM #
10
4
7
5
500257-1
GASKET (CAP)
502508
QUICKCHECK STEAM CHEST
SWP41V36
REDUCING BUSHING (2" x 1")
503043-2
GASKET (NOZZLE HOLDER)
502890-4
GASKET (STEAM CHEST)
503012
BODY WELDMENT
500203-2
NOZZLE HOLDER
503011
NOZZLE
10
4513K328
1"-3,000# HEX HEAD PLUG
11
4513K324
"-3,000# HEX HEAD PLUG
12
98750A210
"-11 THREADED STUD
13
90521A240
"-11 HEAVY HEX NUT
COMMENTS
15
13
11
QTY
CAP (STEAM CHEST)
14
12
PART DESCRIPTION
500202-9
16
17
18
19
20
21
501915
QUICKCHECK NAMEPLATE
(NOT SHOWN)
22
09-1138-YQ1,2
PERFORMANCE GAGE ROD
(NOT SHOWN)
23
QCP-HTLPA
HYDROSTATIC (LEAK) TEST
TEST @ 22.5 PSIG - NO LEAKS ALLOWED
24
SP-1011-09-1138-6
SURFACE PREP & PAINT
HIGH TEMPERATURE
NOZZLE OFFSET (DISTANCE FROM NOZZLE OUTLET TO DIFFUSER INLET):
NOTICE OF PROPRIETARY RIGHTS
1. FOR SIDE-MOUNTED MOTIVE STEAM INLET, TYPICAL STEAM CHEST ORIENTATION SHOWN.
THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC.
RECEIPT OR POSSESSION THEREOF DOES NOT CONFER OR TRANSFER ANY RIGHT TO MAKE, USE, COPY, MANUFACTURE AND/OR SELL
THIS OR THESE DEVICES BY METHOD SHOWN.
UNIQUE SYSTEMS, ITS LOGO AND QUICKCHECK ARE REGISTERED TRADEMARKS OF UNIQUE SYSTEMS, INC.
QUICKCHECK DEVICES ARE PROTECTED BY U.S. AND FOREIGN PATENTS.
2008 BY UNIQUE SYSTEMS, INC.
2.
3.
4.
ORDER INFORMATION
PURCHASER:
PURCHASE ORDER #:
PROJECT NAME:
PROJECT LOCATION:
EQUIPMENT TAG #:
GENERAL ARRANGEMENT DRAWING #:
1" OUTSIDE
GENERAL NOTES
5.
CERTIFIED CORRECT BY:
GEA POWER COOLING

360-143-1
THE UNIQUE "VIP SERVICE" ADVANTAGE

VALUE INTEGRITY PROFESSIONALISM SERVICE
PHASE II ASTORIA ENERGY EXPANSION PROJECT
KENNETH A. ERIKSEN, V.P.

[email protected]
ASTORIA, NY
2ARC-SKD-002A/B
D-502987
OUTLINE DRAWING #:
REV #
0
1
2
3
DATE
02/15/10
REVISION HISTORY
DESCRIPTION
INITIAL ISSUE
BY
JAP
APP
KAE
NAMEPLATE DATA
SHOP ORDER #:
MOTIVE PRESSURE (MIN):
TYPE 62E STEAM JET EJECTOR (Y-STAGE)
SERIAL #:
09-1138
210
PSIG
BACK PRESSURE:
MOTIVE TEMPERATURE:
PSIA
700
09-1138-YQ1 & -YQ2
WWW.UNIQUESYSTEMS.COM
PART #
BILL OF MATERIAL
ITEM #
15
12
10
16 17
14
11
1
9
2
13
PART DESCRIPTION
QTY
500211-9
CAP (STEAM CHEST)
500257-7
GASKET (CAP)
502697
QUICKCHECK STEAM CHEST
SWP41V31
503043-8
GASKET (NOZZLE HOLDER)
502890-1
430120-2
SUCTION CHAMBER
500887-7
NOZZLE HOLDER
503013
NOZZLE
10
443409-4
GASKET (DIFFUSER)
11
503014
DIFFUSER
12
4513K324
13
4513K324
14
98750A210
"-11 THREADED STUD
15
90521A240
"-11 HEAVY HEX NUT
16
98750A210
"-11 THREADED STUD
17
90521A240
"-11 HEAVY HEX NUT
COMMENTS
18
19
20
21
501915
NAMEPLATE
(NOT SHOWN)
22
09 1138 ZQ1 2
09-1138-ZQ1,2
PERFORMANCE GAUGE ROD
(NOT SHOWN)
23
QCP-HTLPA
24
SP-1011-09-1138-6
HIGH TEMPERATURE SERVICE
THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC
2.
3.
4.
ORDER INFORMATION
PURCHASER:
PURCHASE ORDER #:
PROJECT NAME:
PROJECT LOCATION:
EQUIPMENT TAG #:
" OUTSIDE
GENERAL NOTES
5.
GEA POWER COOLING

360-143-1


[email protected]
ASTORIA, NY
2ARC-SKD-002C/D
D-502987
OUTLINE DRAWING #:
REV #
0
1
2
3
DATE
02/15/10
REVISION HISTORY
DESCRIPTION
INITIAL ISSUE
BY
JAP
APP
KAE
NAMEPLATE DATA
SHOP ORDER #:
TYPE 32E STEAM JET EJECTOR (Z

(Z-STAGE)
STAGE)
SERIAL #:
09-1138
210
PSIG
BACK PRESSURE:
15.7
PSIA
MOTIVE TEMPERATURE:
700
09-1138-ZQ1
09 1138 ZQ1 & -ZQ2
ZQ2
PART #
BILL OF MATERIAL
ITEM #
11
12
1
10
PART DESCRIPTION
QTY
COMMENTS
503016
BODY WELDMENT
502742-8
STEAM CHEST
503015
NOZZLE
440331-2
NOZZLE SPACER
446109-5
EXTENSION
446109-5
EXTENSION
440331-2
EXTENSION SPACER
440331-2
EXTENSION SPACER
502890-4
10
SWP41V43
11
4513K326
1"-3,000# HEX HEAD PLUG
12
4513K324
13
98750A210
"-11 THREADED STUD
14
90521A240
"-11 HEAVY HEX NUT
15
SWP41V38
(NOT SHOWN)
22
501914
EJECTOR NAMEPLATE
(NOT SHOWN)
23
QCP-HTLPA
24
SP-1011-09-1138-6
HIGH TEMPERATURE SERVICE
16
17
18
19
20
21
THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC
2.
3.
4.
ORDER INFORMATION
PURCHASER:
PURCHASE ORDER #:
PROJECT NAME:
PROJECT LOCATION:
EQUIPMENT TAG #:
" OUTSIDE
GENERAL NOTES
5.
GEA POWER COOLING

360-143-1


[email protected]
ASTORIA, NY
2ARC-SKD-003
B-502993
OUTLINE DRAWING #:
REV #
0
1
2
3
DATE
02/15/10
REVISION HISTORY
DESCRIPTION
INITIAL ISSUE
BY
JAP
APP
KAE
NAMEPLATE DATA
SHOP ORDER #:
8" x 8"
8
8 STEAM JET EJECTOR (DEAERATOR)
SERIAL #:
09-1138
210
PSIG
BACK PRESSURE:
MOTIVE TEMPERATURE:
PSIA
700
09-1138-DA
09 1138 DA
8
6
14 13
PART #
BILL OF MATERIAL
ITEM #
15
12
4
PART DESCRIPTION
QTY
502721
CHAMBER (HOUSING)
502722
INLET COVER
502723
OUTLET COVER
502269
COVER GASKET
502724
VALVE FLOAT
502725
VALVE STEM
502726
VALVE POPPET
502727
VALVE SEAT
COMMENTS
90298A537
LIMIT SCREW
10
9557K462
O-RING
11
9557K477
O-RING
12
92196A542
SOCKET-HEAD CAP SCREW
16
13
502347
NAMEPLATE
(NOT SHOWN)
14
16055T237
FLOW ARROW
(NOT SHOWN)
15
4513K324
22
QCP-HTLPA
PRESSURE TEST
TEST @ 22.5 PSIG - NO LEAKS
23
SP-1012
DRAINER VALVE ONLY
24
SP-1013
PIPING & ACCESSORIES
PART #
16
11
17
18
19
12
20
10
21
9
3
REBUILD KIT (INCLUDES ITEMS # 4 THRU 12):
1. THIS IS A VARIABLE FLOW CONDENSATE DRAIN TRAP (MAX FLOW: 7,000 #/HOUR).
THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC.
UNIQUE SYSTEMS AND ITS LOGO ARE REGISTERED TRADEMARKS OF UNIQUE SYSTEMS, INC.
2.
3.
4.
ORDER INFORMATION
PURCHASER:
PURCHASE ORDER #:
PROJECT NAME:
PROJECT LOCATION:
EQUIPMENT TAG #:
OUTLINE DRAWING #:
REV #
0
1
2
3
DATE
02/15/10
502720-99
GENERAL NOTES
GEA POWER COOLING, INC.

360-143-1

PHASE II ASTORIA EXPANSION PROJECT

[email protected]
ASTORIA, NY
2ARS-M-012 / 2ARS-M-013
D-502987 / B-502925 (DRAINER ARRANGEMENT)
B-502776
REVISION HISTORY
DESCRIPTION
INITIAL ISSUE
5.
BY
JAP
APP
KAE
NAMEPLATE DATA
SHOP ORDER #:
PART #:
MODEL # 2VCD
2VCD-20B
20B VACUUM CONDENSATE DRAINER SERIAL #:
09-1138
502720
VALVE TYPE:
TAG / ITEM #:
DRAINER
2ARS-M-012, -013
09-1138-VCD1 2
09-1138-VCD1,2
E-Mail: [email protected] Website: www.uniquesystems.com
RECOMMENDED SPARE PARTS LIST

UNIQUE SYSTEMS SO#:
CUSTOMER:
CUSTOMER PO#:
PROJECT:
LOCATION:
09-1138
GEA POWER COOLING
360-143-1
09-360
DATE:
REVISION:
PROJECT ENGINEER:
CHECKED:
QUOTE VALIDITY:
GA BOM #
5-Years
2-Years
Operational
Line #
Category
Part Number
2
2
2
2
2
17
5
6
7
8
9
503011
Y-STAGE (62E)
500202-9
500203-2
503043-8
502890-4
500257-1
502657-99
10
11
12
0911383000-02
3
3
503013
503014
14
15
17
18
19
20
21
22
500211-9
500887-7
503043-8
502890-1
500257-7
443409-4
503018-99
23
24
25
26
9
9
9
502720-99
0911382997-38
0911382992-03
09-11382985-01-99
29
27
26
24
22
23
0911382999-01
0911382998-03
0911382998-04
0911382998-06
0911382998-05
0911382998-01
27
28
31
32
33
34
35
36
31
37
38
4
8
39
40
MISCELLANEOUS
29
30
0911382992-02
0911382990-02-99
0911382990-03-99
41
5
6
7
10
13
14
15
42
43
44
45
46
47
48
0911382990-05
0911382997-01
0911382992-06
0911382997-38
0911382997-29
0911382997-37
0911382991 02
0911382991-02
Part Description
EJECTOR NOZZLE
Quickcheck Nozzle (62E)
GASKETS, SPACERS, ETC.
Cap, Quickcheck Steam Chest
Nozzle Holder
Gasket, Nozzle Holder
Gasket, Steam Chest
Gasket, Cap (Steam Chest)
Gasket Set, Target Tee
MISCELLANEOUS
Relief Valve, Ejector Body
EJECTOR NOZZLE & DIFFUSER
Quickcheck Nozzle (32E)
Diffuser (Venturi)
(Venturi), Z-Stage
Z Stage
Cap, Quickcheck Steam Chest
Nozzle Holder
Gasket, Nozzle Holder
Gasket, Steam Chest
Gasket, Cap (Steam Chest)
Gasket, Diffuser
Gasket Set, Discharge Manifold
DRAINERS, CONDENSATE
Vac Cond Drainer Rebuild Kit
Ball Valve
Strainer
HEAT EXCHANGER
IC/AC Gasket Set
INSTRUMENTATION
Air Flow Meter
Pressure Gauge, Steam
Pressure Gauge, Vacuum
Temperature Gauge, Steam
Temperature Gauge, Process
Thermowell, Temp Gauge
MISCELLANEOUS
2" SW Strainer
VALVES, ACTUATED
10"-150# Motorized Buttefly Valve
2" Motorized Ball Valve, Complete
VALVES, MANUAL
6"-150# Manual Butterfly Valve
6"-150# Manual Gate Valve
2" NPT Ball Valve
1" SW Globe Valve
1/2" NPT Ball Valve
Block & Bleed Valve
Comments
S/N 09-1138-YQ1,2
Tag Numbers
2ARC-SJ-002A,002B
2
2
4
4
4
2
$
$
$
$
$
$
$
$
$
$
$
$
2ARC-PSV-001A,001B
2ARC-SJ-002C,002D
2
2
$
$
$
$
2
2
4
4
4
4
2
$
$
$
$
$
$
$
$
$
$
$
$
$
$
See Note 'A'

See Note 'A'
See Note 'A'
See Note 'B'
2ARS-M-012,013
2ARC-V-208,209,210,212,213,214
2ARC-M-018,019
2
1
1
$
$
$
$
$
$
S/N 09-1138-IC/AC
2CNM-HEX-003
2ARC-FI-0130
2ARC-PI-0201
2ARC-PI-0124,0127
2ARC-TI-0201
2ARC-TI-0128,0129,0202
1
1
1
1
1
1
$
$
$
$
$
$
$
$
$
$
$
$
2ARC-M-010
2ARC-MOV-0170
2ARC-MOV-0123
1
1
$
$
$
$
2ARC-V-202A,202B
2ARC-V-203A,203B
2ARC-V-205A,205B
2ARC-V-206
2ARC-V-204A,204B
2ARC-V-207,211
2ARC V 0127 0201 0202
2ARC-V-0127,0201,0202
1
1
1
1
1
1
1
$
$
$
$
$
$
$
$
$
$
$
$
$
$
See Note 'C'

No Spares Available
51
52
53
SYSTEM MODEL #: 82E (8" x 8")
55
56
Category
Part Number
503015
440331-2
446109-5
502890-4
0911383000-01
57
58
59
60
61
10
11
8
9
0911382998-03
0911382998-04
0911382998-06
0911382998-02
13
0911382992-01
0911382990-04-99
2
3
5
7
0911382990-07
0911382997-02
0911382997-29
0911382991-02
62
63
64
65
66
67
68
69
70
Part Description
EJECTOR NOZZLE
Nozzle (82E)
Spacer, Nozzle & Extension
Extension, Nozzle
Gasket, Steam Chest
MISCELLANEOUS
Relief Valve, Ejector Body
INSTRUMENTATION
Pressure Gauge, Steam
Pressure Gauge, Vacuum
Temperature Gauge, Steam
Thermowell, Temp Gauge
MISCELLANEOUS
1" SW Strainer
VALVES, ACTUATED
1" Motorized Ball Valve, Complete
VALVES, MANUAL
8"-150# Manual Gate Valve
1" SW Globe Valve
Block & Bleed Valve
Comments
S/N 09-1138-DA
Tag Numbers
2ARC-SJ-003
Extended
Price
Unit Price
3
2
2
$
$
$
$
$
$
2ARC-PSV-003
2ARC-PI-0204
2ARC-PI-0203
2ARC-TI-0203
1
1
1
1
$
$
$
$
$
$
$
$
2ARC-M-011
2ARC-MOV-0010
2ARC-V-001
2ARC-V-215
2ARC-V-217
2ARC-V-0204,0203
1
1
1
1
$
$
$
$
$
$
$
$
See Note 'A'
No Spares Available
Skid Skid Skid Skid

"A" "B" "C" "D"
Delivery
(Estimated)
8-10 WEEKS / ARO
54
1
1
1
Delivery
(Estimated)
Recommended Quantity
On-Hand
DEAERATOR (82E)
GA BOM #
5-Years
2-Years
Operational
Line #
50
Extended
Price
Unit Price
$
See Note 'A'

See Note 'A'
See Note 'A'
S/N 09-1138-ZQ1,2
Skid Skid Skid Skid

"A" "B" "C" "D"
GA DWG #: 502993
49
NET 30 DAYS
FOB (FCA) SHIPPING POINT
8-10 WEEKS / ARO
3
3
3
3
3
3
18
16
Z-STAGE (32E)
12
13
09-1138 -RSPL
Recommended Quantity
On-Hand
1
3
DOC NO.
QUOTE #:
PAYMENT TERMS:
FREIGHT TERMS:
SYSTEM MODEL #: 62C32C
GA DWG #: D-502987
9/10/2010
0
DSB
KAE
9/9/2011
NOTES
A.
B.
C.
D.
E
E.
To avoid steam or air leakage, if seals are broken during maintenance, gaskets MUST be replaced.
Vacuum Condensate Drainer Rebuild Kit consists of valve float, stem, poppet, seat, limit screw, o-rings, cover gaskets & cap screws.
Actuated Valve Rebuild Kit consists of EPDM seat only, actuator hardware kit & retaining ring.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
All quoted prices are in U.S. Dollars and exclude duties, fees & taxes associated with the export of goods outside the United States which is the responsibility of Purchaser.
A $250 minimum order value (excluding freight charges) applies to all spare part orders.
Unless otherwise noted, selling terms for spare parts are strictly FOB (FCA) SHIPPING POINT & NET 30 DAYS (with approved credit). Unique Systems reserves the right to require progress payments.
Overdue payments shall be subject to interest charges at the rate of eighteen (18%) percent per annum (1.5% per month) or the maximum rate permitted by applicable law, whichever is less.
Any purchase order shall be interpreted and governed by the laws of the State of New Jersey and any disputes arising from an order shall be resolved only in that jurisdiction.
Title of goods, materials or services shall not pass from Seller to Purchaser until all invoices are paid-in-full.
Domestic packaging is included in quoted prices. Export-quality packaging (ie. wood crates, heat-treated lumber, waterproofing, fumigation services, etc.) is available at additional cost.
All machined, custom-fabricated and/or special order components are subject to cancellation charges quoted at the time of cancellation.
A 25% re-stocking fee applies to stock components which are returned in new, resaleable condition. We cannot accept returns of custom-fabricated, machined or special order items.
These Terms & Conditions represent the selling terms of our offer. Notice is hereby given that any terms or conditions contrary to those indicated above are rejected.
TERMS & CONDITIONS
WARRANTY & GUARANTEE

Unique Systems warrants that replacement parts and equipment will be free from defects in design, workmanship and material, for a period of one (1) year from the date of shipment, normal wear and tear and corrosion excepted. Any parts or equipment designed and manufactured by others but furnished by us will be repaired or replaced
only to the extent of the original manufacturer's guarantee. Our warranty is limited to the cost of repair or replacement of items, and shall not include removal, shipment or re-installation of any items, except to the extent that Unique Systems was required to incur such costs for the original supply of the item. Unique Systems will in no event
be liable for any special or consequential damages and our liability is limited to the purchase price of the item affected. Our warranty will not apply to any equipment that has been subject to misuse, negligence, accident, or which has been modified, altered or repaired by anyone except our authorized employees or representatives. We will
not be liable in any event for modifications, alterations or repairs, except those made with our prior written consent.
CONFIDENTIALITY NOTICE
This document, including any attachments and supporting details, remains the exclusive property of Unique Systems, Inc. It is for the sole use of the intended recipient(s) or entity for which it was prepared. It may contain information that is proprietary, confidential or constitutes trade secrets. Your use of this information constitutes
your agreement to these conditions. If you do not agree with these conditions, you are prohibited from using this information. If you are not the intended recipient, or an employee or agent responsible for delivering this document to the intended recipient, be aware that any review, use, disclosure, dissemination, distribution, storing or
copying of this document, or the use of its contents, is not authorized and is strictly prohibited. Unique Systems will take such action as is necessary to protect its interests if this information is misused. If you have received this document and are not the intended recipient, you must notify us immediately and return the entire, original
document at our expense.
SECTION 9
SYSTEM DESIGN SPECIFICATIONS
Information in this section is intended to provide the operator with critical information on the ejector system relative to
expected performance and original design specifications.
HOLDING EJECTOR SKID DATA SHEET

S.O. #: 09-1138
1
2
3
6
7
8
REVISION:
CUSTOMER P.O.: 360-143-1

PROJECT: PHASE II ASTORIA ENERGY EXPANSION PROJECT
4
5
DATE:
CUSTOMER: GEA POWER COOLING
DOC NO.
09-1138 -SDS
ENGINEER:
DSB
CHECKED:
WPS
PROJECT #: 09-360
CONTRACTOR: SNC LAVALIN CONSTRUCTOR
CONTRACT #: 0620
LOCATION: ASTORIA, NY
SYSTEM MODEL NO. 62C32C
9
10
07/19/10
SYSTEM PROCESS DESIGN
200% CAPACITY
11
12
DESIGN POINTS
100% CAPACITY
CASE A
CASE B
UNITS
HEI
MAXIMUM
CASE C
CASE D
---
HEI
MAXIMUM
---
NOTES
13
TURBINE STEAM FLOW
LB/HR
---
---
---
---
---
---
---
14
VACUUM SYS. SUCTION PRESSURE
In HgA
---
---
---
15
SUCTION SUBCOOL
7.5
7.5
---
7.5
7.5
---
---
16
SUCTION TEMPERATURE
71.5
152.2
---
71.5
152.2
---
---
17
VAPOR SUCTION LOAD (STEAM)
LB/HR
297.0
1652.0
---
148.5
826.0
---
---
18
SUCTION LOAD (AIR)
LB/HR
135.0
135.0
---
67.5
67.5
---
---
19
SUCTION LOAD (DAE)
LB/HR
501.7
2200.0
---
250.8
1100.0
---
---
20
COOLING WATER SOURCE
---
CONDENSATE
CONDENSATE
---
CONDENSATE
CONDENSATE
---
SAME MAIN COND.

---
21
COOLING WATER INLET TEMP.
22
COOLING WATER FLOW
23
MAX. COOLING WATER P ALLOWED
24
AMBIENT TEMPERATURE
25
AMBIENT PRESSURE
26
79
157
---
79
157
---
LB/HR
1588500
1750000
---
1588500
1750000
---
---
PSI
5.1
5.1
---
5.1
5.1
---
NTE
11 - 95
11 - 95
---
11 - 95
11 - 95
---
---
In HgA
29.9
29.9
---
29.9
29.9
---
---
UNITS
EJECTORS
VACUUM PIPING
MOTIVE STEAM
DRAINS
SHELL SIDE
TUBE SIDE
SILENCER
750
250
750
250
600
250
N/A
MECHANICAL DESIGN
27
DESIGN POINTS
28
DESIGN TEMPERATURE
29
DESIGN PRESSURE
PSIG
15 + F
F.V.
V
15 + FV
250
15 + FV
100 + FV
500
N/A
30
TEST PRESSURE
PSIG
22.5
22.5
325
22.5
130
650
N/A
31
EJECTOR PERFORMANCE
32
DESIGN POINTS
UNITS
Y-STAGE
Z-STAGE
DEAERATOR
NOTES
33
NOMINAL DESIGN CAPACITY
SCFM
15
15
0.9
PER ELEMENT
---
---
---
34
EVACUATION VOLUME
FT3
N/A
N/A
N/A
---
---
---
-----
35
EVACUATION TIME
36
SUCTION PRESSURE
MIN
N/A
N/A
N/A
---
---
---
In HgA
1.00
9.50
2.00
---
---
---
37
SUCTION TEMPERATURE
---
71.5
163.6
120
---
---
---
---
38
39
VAPOR SUCTION LOAD (STEAM)
LB/HR
148.5
198.0
496
---
---
---
---
VAPOR SUCTION LOAD D.A.E.
LB/HR
183.3
244.4
612.3
---
---
---
---
40
SUCTION LOAD (AIR)
LB/HR
67.5
67.5
4.0
---
---
---
---
41
SUCTION LOAD (OTHER NCG)
LB/HR
N/A
N/A
N/A
---
---
---
---
42
SUCTION LOAD (OTHER VAPOR)
LB/HR
N/A
N/A
N/A
---
---
---
---
43
SUCTION LOAD (DAE TOTAL)
LB/HR
250.8
311.9
616.3
---
---
---
---
44
DESIGN DISCHARGE PRESSURE
In HgA
10.00
32.00
3.00
---
---
---
---
45
MAX. 2-STAGE OPERATING RANGE
In HgA
1-8
N/A
N/A
---
---
---
---
46
OPER. MOTIVE STEAM PRESSURE
PSI
210
210
210
---
---
---
---
47
OPERATING MOTIVE STEAM TEMP
700
700
700
---
---
---
---
LB/HR
945
687
388
---
---
---
---
48
49
MOTIVE STEAM CONSUMPTION
MATERIALS OF CONSTRUCTION
50
EJECTORS
CONDENSERS
SILENCER
51
STEAM CHEST
52
NOZZLE
53
SUCTION CHB.
A106B / A285C
T. SHEETS
A516
PIPING
54
DIFFUSER
A285C / C1018
BONNETS
A106B
EXT. FINISH
55
EXT. FINISH
BAFFLES
A36
57
PIPING
SHELL
A106B
SHELL
N/A
EJECTOR
DI, CI
VACUUM SIDE
A106B
316 SS
TUBES
A249
INTERNALS
N/A
MOTIVE STEAM
A106B
MOTIVE SIDE
A106B
N/A
VACUUM RELIEF
B584
CW SIDE
N/A
TUBESIDE RELIEF
N/A
EXT. FINISH
SP-1011-09-1138-6
AC VENT
EXT. FINISH SP-1012-09-1139-06
56
VALVES
A106B / A516
INSTRUMENT
NOTES
58 1. EXTERIOR FINISH APPLIES TO FABRICATED COMPONENTS ONLY. VALVES, ETC., RECEIVE MFR'S STD TOP COAT.
59 2. MOTIVE STEAM CONDITIONS REQUIRED AT CUSTOMER STEAM INTERFACE CONNECTION SPECIFIED ON GA DWG.
60 3. MECHANICAL DESIGN TEST PRESSURE PER ASME CODE WHERE APPLICABLE.
Page1of1
DI, CI
SS
N/A
SP-1011
SP-1011-09-1138-6
Y-STAGE EJECTOR PERFORMANCE CURVE

1
2
3
4
5
6
7
8
9
10
11
12
13
S.O. #:
CUSTOMER:
CUSTOMER P.O.:
PROJECT:
PROJECT #:
CONTRACTOR:
CONTRACT #:
LOCATION:
09-1138
GEA POWER COOLING
360-143-1
09-360
SNC LAVALIN CONSTRUCTOR
0620
ASTORIA, NY
DATE:
REVISION:
ENGINEER:
CHECKED:
10/09/09
2
DSB
PWL
DOC. NO.
SYSTEM MODEL NO.
09-1138 -PCY
62C32C
EJECTOR SERIAL NO. 09-1138-YQ

OPERATING CONDITIONS
MOTIVE STEAM PRESSURE:
MOTIVE STEAM TEMPERATURE:
DESIGN DISCHARGE PRESSURE:
210 PSIG
700 F
10.00 IN. HgA
15
14
Discharge Pressure Curve
13
12
11
10
Pressure - In. HgA
9
8
7
6
5
4
Suction Pressure Curve
3
2
1
DESIGNPOINT:250.8LB/HR@1"HGA
0
200
400
600
800
Capacity - Lbs/Hr D.A.E.
Page1of1
1000
1200
Z-STAGE EJECTOR PERFORMANCE CURVE

1
2
3
4
5
6
7
8
9
10
11
12
13
S.O. #:
CUSTOMER:
CUSTOMER P.O.:
PROJECT:
PROJECT #:
CONTRACTOR:
CONTRACT #:
LOCATION:
09-1138
GEA POWER COOLING
360-143-1
DATE:
REVISION:
ENGINEER:
CHECKED:
09-360
0620
ASTORIA, NY
10/09/09
2
DSB
PWL
DOC. NO.
SYSTEM MODEL NO.
09-1138 -PCZ
62C32C
EJECTOR SERIAL NO. 09-1138-ZQ

210 PSIG
700 F
32 IN. HgA
35
30
25
Pressure - In. HgA
20
15
10
DESIGNPOINT:311.9LB/[email protected]"HGA
0
300
400
500
600
Page1of1
700
800
DA FORWARDING EJECTOR PERFORMANCE CURVE

1
2
3
4
5
6
7
8
9
10
11
12
13
S.O. #:
CUSTOMER:
CUSTOMER P.O.:
PROJECT:
PROJECT #:
CONTRACTOR:
CONTRACT #:
LOCATION:
09-1138
GEA POWER COOLING
360-143-1
09-360
0620
ASTORIA, NY
DATE:
REVISION:
ENGINEER:
CHECKED:
10/08/09
2
DSB
PWL
DOC. NO.
SYSTEM MODEL NO.
09-1138 -PCD
62C32C
EJECTOR SERIAL NO. 09-1138-DA

210 PSIG
700 F
4 IN. HgA
25
Pressure - In. HgA
20
15
10
DESIGN POINT:616.3LB/HR@2"HGA
0
600
700
800
900
Page1of1
1000
1100
SECTION 10
DRAWINGS
This section contains copies of drawings submitted to the purchaser during the Engineering Stage of the project. They
are included in this manual to assist the user in operation, maintenance, and troubleshooting the equipment.
SECTION 11
CATALOG CUTS AND COMPONENT MANUALS
Catalog cuts for components are attached to aid the user with operation, maintenance, and troubleshooting where
applicable. OEM manuals are included for special components as necessary per specific project requirements. The
operator is advised to carefully study the attached manuals for information on the proper operation and maintenance of
critical system components.
Depending on the specifics of the order, however, none may be required. Consult Unique Systems for detailed
questions or concerns regarding specific component operation not addressed in this section of the manual.
SECTION 12
SPECIAL INSTRUCTIONS
QUICKCHECK EJECTORS
Uniques patented Quickcheck Ejectors are designed to facilitate component inspections with minimized system
downtime. With the Quickcheck design the operator can quickly gauge critical ejector geometry parameters, namely
steam nozzle throat and diffuser throat diameters, without taking apart the system or removing the ejector from the skid.
Reference the Quickcheck figures in the following pages for detailed instructions on assembly and disassembly of
Quickcheck ejectors.
To determine if your system was supplied with Quickcheck Ejectors refer to the Ejector Bills of Materials in SECTION 8
of this manual. If your ejectors are not Quickcheck contact Unique Systems for assistance with the disassembly
procedure for your particular system.
TOUCH-UP PAINTING
Touch-up painting may be required from time to time, especially if the unit is installed outdoors. For outdoor installations
routine maintenance should include periodic checks on paint integrity. When small amounts of paint (6 sq. or less)
flake or chip exposing the bare metal underneath, rusting will occur and repairs should be made immediately.
To repair the rust spot first use a wire brush or a small power tool to scrape away rust leaving only the clean metal
surface. Apply two coats of primer as directed by the paint specifications included with this manual (SECTION 15).
Then apply one coat of finish paint.
If rusting or painting damage is severe contact Unique Systems for recommendations particular to your system and
ambient conditions.
RUST INHIBITORS
Rust inhibitor is applied to all flanged connection faces and exposed threaded pipe connections at Uniques factory.
However, should the need arise where another application of inhibitor is required we recommend using the following
coatings. Follow the manufacturers directions for specific instructions and product details.
1. Rust Veto 344
E. F. Houghton & Co.
2. Industrial SP-400 03282
CRC Industries
When cleaning is required the following solvents are recommended for use with the rust inhibitor coatings listed. Follow
the manufacturers directions for specific instructions and product details.
1. Dykem Remover
2. Paint Thinner
3. Mineral Spirits
SECTION 13
FORMS
The attached forms are provided for the user to assist with various requirements of installation, storage, spare parts
ordering, and problem troubleshooting. Included are the Receiving Inspection & On-Site Storage Inspection forms.
Please contact Unique Systems if you have any questions or need assistance completing a required form.
QC FORM 1020RI
UNIQUE SYSTEMS, INC.
RECEIVING
INSPECTION
1 Saddle Road Cedar Knolls, NJ 07927-1998 (USA)

Phone:
Fax:
Email:
SERIAL #
(973) 455-0440
(973) 455-7214
[email protected]
PURCHASE ORDER #
DELIVERY DATE:
SHIPPING DIM'S
SHIP DATE
SHIPPING WEIGHT
UNIQUE SHIPPING INSPECTOR
REC. INSPECTOR
SHIP DATE
CUSTOMER:
Please note below any shortages, damage, or other problems with this delivery.
ITEM #
PART NUMBER
DESCRIPTION OF DAMAGE OR SHORTAGE
QTY.
ACCEPTED/REJECTED
NOTES:
Attach signed BOL, digital photographs, and any other

applicable documentation to prove claim.
This form and associated documentation must be returned to Unique
within one (1) week of delivery or claims may be rejected.
Completed By:
Date Completed:
STORAGE
INSPECTION LOG
QC FORM 1030SI
UNIQUE SYSTEMS, INC.

1 Saddle Road Cedar Knolls, NJ 07927-1998 (USA)
Phone:
Fax:
Email:
SERIAL #
(973) 455-0440
(973) 455-7214
[email protected]
PURCHASE ORDER #
START DATE:
COVERED
DELIVERY DATE
SPACE HEATERS
INTO STORAGE DATE
STORAGE INSP
RECEIVING INSPECTOR
STORAGE LOCATION
MONTHLY INSPECTION IS REQUIRED TO MAINTAIN WARRANTY VALIDITY

INSP
DATE
COMPONENT
CONDITION
INSP BY
CORRECTIVE ACTION
NOTES:
Note any damage or other problem immediately.

Digital photographs required for record and warranty claims.
This form and associated documentation must be kept for record.
Signed copy required for warranty and service claims.
Date Removed
Installation Date
SECTION 14
WARRANTY & CLAIMS
The following documentation is provided for reference regarding Uniques standard warranty policy. In the case of
equipment malfunction, Uniques warranty coverage is provided to assist the customer with repairs and/or replacement
parts per the terms included. Should the need arise, a Warranty Claim Form is attached. All claims to Unique Systems
must be accompanied by a completed form. Claims will not be processed without the proper documentation and repairs
will not be approved without the explicit written consent of Unique Systems.
WARRANTY
Unique Systems warrants that all new Process Vacuum Systems & equipment will be free from
defects in design, workmanship and material for a period of TWO (2) YEARS from the date of
shipment or ONE (1) YEAR from the date of installation, whichever occurs first. Spare parts will
be warranted for a period of ONE (1) YEAR from shipment. Any claims for defective products
must be made in writing to Unique Systems and the item in question must be returned to our
factory for evaluation. Items found to be defective will either be repaired or replaced, at our
discretion, free of charge. Shipping terms for all warranty items are Ex-Works Factory.
The following conditions are not considered to be defects in design or workmanship:
Normal Wear & Tear
Corrosion
Improper Handling
Erosion
Improper Storage
Rubbing
Our warranty will not apply to any equipment that has been subject to misuse, negligence,
accident, or which has been modified, altered or repaired by anyone except our authorized
employees. We will not be liable in any event for modifications, alterations or repairs, except
those made with our prior written consent.
Any parts or equipment designed and manufactured by others but furnished by us will be
repaired or replaced only to the extent of the original manufacturer's guarantee.
Our warranty is limited to the cost of repair or replacement of items, and shall not include
removal, shipment or re-installation of any items, except to the extent that Unique Systems was
required to incur such costs for the original supply of the item. In such instances, we must
have free & open access to our equipment for any warranty repairs.
Unique Systems, its officers, employees or representatives, shall in no event be held liable for
any consequential, incidental, or subsequential damages or expenses arising from the use or
misuse of our products. Our liability is limited to the purchase price of the item affected,
excluding any emergency premiums or expediting fees.

01/ 2009
DOCUMENT #:
DOCUMENT TITLE:
CONTROLLED BY:
Q.C. FILE:
QCF-590
WARRANTY CLAIM FORM

Alexander J. Sosa, Engineering/Q.A. Manager
Operations/Quality Control/QCF Quality Control Forms
CLAIM REFERENCE
Date:
Claimant Company:
Warranty Claim #:
Contact:
Entered By:
Phone:
System Serial #:
E-mail:
System Type:
Site Address:
System Ship Date:

Warranty Exp. Date:
CLAIM DESCRIPTION
[ ] SYSTEM PERFORMANCE
[ ] DAMAGED PART
[ ] Poor Vacuum
Part Number:
[ ] Inadequate Capacity
Part Description:
Brief Problem Description:
CLAIM INSTRUCTIONS
This portion of the form is intended to be completed
by the claimant and returned to Unique Systems.
Please review Unique Systems Warranty Policy
(attached) and check one of the following options:
A, B, or C. A purchase order is required for all
options. Upon receipt of the damaged part(s) and
determination that the damage is covered under
warranty Unique Systems will void your P.O.
When requesting replacement parts also check
option A for Unique Systems on-site supervision of
installation if desired by customer. No travel
arrangements will be made until a customer P.O is
received when on-site services are requested.
After selecting the desired claim option please
complete the customer authorization section below.
CLAIM OPTIONS
A[]
Engineering field service personnel requested

on site (at location listed above).
B[]
Damaged parts to be removed by the User and

returned to Unique Systems, freight prepaid,
for review prior to replacement.
C[]
Replacement parts to be sent to and installed

by the User prior to return of damaged parts to
Unique Systems for review.

Pg. 1 of 2
DOCUMENT #:
DOCUMENT TITLE:
CONTROLLED BY:
Q.C. FILE:
QCF-590
WARRANTY CLAIM FORM

Alexander J. Sosa, Engineering/Q.A. Manager
Operations/Quality Control/QCF Quality Control Forms
Notes
1. Unique Systems considers any complaint by the User and/or the purchaser regarding system
performance or damaged parts to be a warranty claim provided that the warranty coverage period is in
effect at the time of the call or communication. The validity and extent of said claim will be determined
by Unique Systems as governed by Unique Systems Warranty policy.
2. A Warranty Claim Form completed in its entirety, including digital photographs, is a prerequisite for
claim processing and corrective action by Unique Systems.
3. This form must be returned complete to Unique Systems within 3 calendar days of issue in order to
ensure a prompt response and expedient claim processing.
4. After evaluating the warranty claim part(s) received it is determined that part(s) are damaged due to
causes not covered by our warranty, or that the part(s) are not defective, Unique Systems will invoice
against the purchase order on file. If the warranty claim parts are not received by Unique Systems
within 30 days of the User receiving the replacement part(s) the customer forfeits claim rights and the
purchase order on file will be charged.
5. All parts being returned must be thoroughly cleaned and totally free of any hazardous material. Parts
must be marked with the warranty claim number as shown above and sent freight prepaid.
6. Service personnel rates are portal to portal. Saturdays are billed at time and a half; Sundays and locally
observed holidays are billed at double time. Travel and living expenses are charged at cost, based on
Economy Class airfare for domestic travel, Business Class for overseas travel. See Unique Systems field
service rate sheet for current rates and more details.
CUSTOMER AUTHORIZATION
Unique Systems is authorized to proceed with this warranty claim as noted. All terms included are accepted.
[ ] Replacement Parts Required
[ ] Engineering Field Service Required On Site
Customer Purchase Order Number:
Authorized by:
-
Name
Title
Date
Note: A formal P.O. must accompany this completed form in order for claim processing to proceed.
Form Rev. 2 AJS 07/23/10

Pg. 2 of 2
SECTION 15
QC DOCUMENTATION
Quality documentation is an integral part of every system delivered by Unique Systems. Included in this manual by
reference is Unique Systems QC Dossier which incorporates a compilation of quality documents required by the
purchase order. This document package is provided for permanent record purposes, intended to verify scope of
supply, materials of construction, testing, etc. However, it is not represented as being a complete listing of all quality
related documents associated with the manufacture of this equipment.
The QC Dossier is submitted under separate cover as a stand-alone document. Please reference the dossier for all
quality related documentation pertinent to this order.

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SYSTEM MODEL 62C32C

SERIAL No. 09-1138

*** CAUTION ***

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STUDY THIS MANUAL!!

*** WARNING ***

PERMISSION TO MAKE COPIES OF THIS MANUAL

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EXHAUST (VENT) PIPING

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SYSTEM INSTALLATION AND CHECK-OUT

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* CAUTION *

* WARNING *