Saving energy in
plastics profile extrusion
Vacuum units
Speed controlled vacuum pumps
Speed controlled side channel blowers
Highest energy efficiency for any kind of application
BluSystems The system for saving energy
An adequate, decentralised
creation of vacuum with highest
energy efficiency.
BluVac
BluLine
BluLine
Type
Vacuum unit
Liquid ring vacuum pump
Side channel blower
Series
VI-BV series
VG and VN series
VB series
Frequency controller



Pressure level sensor



Operating panel



Discharge pump

Double mechanical seal housing

Water level sensor

Separator tank

without water output
or water output is sufficient through the
vacuum pump
without water output and
with low vacuum requirement
Application
2
with water output
Subject to technical modifications and error.
11/2013 | 1096.1044
Easy to handle and maximum flexibility
Common components
BluVac and BluLine vacuum units have pressure sensors, frequency
converters und operating panels respectively.
Both systems are decentralised and regulate one pressure level
respectively. The
soft-start ramp of the frequency converters reduces harmful mechanical and electrical loads during the peaks of the start-up process.
BluSystems
operating
panel
Easy to handle
The machine operator adjusts the required nominal value of the
pressure level. The regulation makes sure that the nominal value is
being adhered to.
The machine setter is able to configurate the vacuum unit and to
read out the operating parameters with the operating panel.
Operating panel 4
Pressure level 4
BluLine vacuum unit with
vacuum pump type VG
BluLine vacuum unit with
side channel blower type VB-140
BluLine vacuum units with
vacuum pumps
BluLine vacuum units with
side channel blower
This is the solution for
applications without water
output or where the vacuum
pump is able to convey the
arising water amount itself.
Liquid ring vacuum pumps
of the reliable ranges VG and
VN – equipped with frequency
converter, sensor and operating
panel.
Suitable for a lower vacuum
without water output.
They are protected against
humidity in the area of the
bearings and therefore reach
a higher lifetime as customary
side channel blowers.
Operating panel 3
Pressure level 3
Operating panel 2
Pressure level 2
Operating panel 1
Pressure level 1
Maximum flexibility
An update of present extrusion series is possible anytime.
Existing pumps or systems can be changed into BluVac or
BluLine vacuum units without any problems.
Parallel operation with conventional vacuum pumps and other
systems is, of course, possible.
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Subject to technical modifications and error.
3
Saving energy as a factor of success
Energy costs are an important part of the operating costs in profile extrusion. If you reduce your energy costs, you increase your
competitiveness on a sustainable basis.
suction capacity /
energy consumption
PIC
Air/
Water
energy saving potential
due to BluVac units
Liquid ring
vacuum pump
Separator
tank
Air
LIC
requirement of suction capacity
Operating
liquid
Water
discharge pump
calibration process (time)
energy consumption of uncontrolled vacuum pumps
energy consumption of BluVac units
Water
Enegery saving potential by BluVac units
Drawing showing mode of operation of a BluVac unit
Lower requirement of suction capacity after the start-up process
BluVac - Intelligent vacuum units reduce operating costs
Mostly vacuum and radial pumps are responsible for the energy
consumption in calibrating tables.
Up to now they have been selected by the high requirement of
suction capacity at the start-up process.
To ensure the significantly low requirement of suction capacity in
the subsequent operating state, systems which work with additional
air or throttle the vacuum pumps on the suction side have been
used until now. Thereby the electrical power consumption of the
vacuum pumps remains high – a gigantic waste of energy.
BluVac vacuum units reduce the energy consumption by creating a
vacuum as required.
The pressure level of the unit and the water level in the separator
tank are continuously being measured by sensors. On the basis
of these measurements the unit is automatically regulating the
pressure level and the water output by adjusting the speed control.
After the start-up process the speed control of the vacuum pump
and the discharge pump is being reduced and therefore the energy
consumption is being reduced significantly. Optimised calibration
tools with minimal air leakage achieve the highest savings.
Enormous energy savings
A calculation example from practice: window profile extrusion
Pre-series models of BluVac vacuum units reached savings of 67 % by a major
manufacturer of window profiles. An existing range was updated with a BluVac
vacuum unit.
Before: After:
Range with 3 uncontrolled vacuum pumps type VN 125,
Electrical power consumption (P1) 3 x 5.2 kW = 15.6 kW
Range with 3 BluVac vacuum units
Electrical power consumption (P1) 3 x 1.1 kW = 3.3 kW
The saved power consumption of 12.3 kW and at estimated 4,000 operating hours
lead to a total of 49,200 kWh per year.
With an estimated € 0.10 per kWh this is a saving of € 4,920.-- per year.
Producing at lower costs – window profile,
manufactured with BluVac vacuum units
4
Additionally the lower requirement of operating liquid of the BluVac vacuum units is
leading to a lower energy consumption for the process water cooling.
The calibration process is being automated by the integrated operating control unit.
The BluVac vacuum compact units amortize fast.
Subject to technical modifications and error.
11/2013 | 1096.1044
All components in a minimum of space
Liquid ring
vacuum pump
Sensor
Pressure opening
vacuum pump
Suction opening
Separator tank
Frequency
controller
Pumps of the VI series,
valve-free version
For monitoring the
pressure level in the
unit
With double mechanical
seal housing,
SAE-flange 1 1/4
For gas / liquid
mixtures,
threaded G 1 1/2
For gas / liquid
mixtures,
stainless steel
PID regulated,
with soft-start-ramp
Discharge pump
Sensor
Pressure opening
discharge pump
Connection for
operating liquid
Maintenance
opening
Operating panel
Radial impeller pump
Type ME-115
For monitoring the
operating liquid level in
the separator tank
With double mechanical
seal housing,
SAE-flange 1 1/4
For liquid ring vacuum
pumps,
with magnetic valve
For cleaning the
separator tank from
residues of the
operating liquid
For regulating the
pressure level
• BluVac vacuum units are designed for calibration
processes with water output.
• The vacuum units fit under every calibration table –
the base area corresponds to a conventional vacuum
pump.
• For the start-up process, when there is temporarily
more requirement of suction capacity, an additional
vacuum pump can be installed.
• BluVac vacuum units are quieter than systems with
noisy additional air supply.
• They are as easy to install as a vacuum pump.
• The vacumm units are valve-free and therefore
guarantee high lifetimes with longer maintenance
intervals – even with contaminated operating liquid.
1096.1044 | 11/2013
Subject to technical modifications and error.
5
Technical data
Characteristic curves vacuum pumps
120
100
2
3
4
5
6
7 8
10
15
20
0
26
70
[m3/h]
Q
[CFM]
60
BluVac VI-130-BV
50
80
40
H
5
10
15
20
25
30
35
Q [U.S.GPM]
40
45
24
H
[m]
Total head
Q
Suction capacity
1
Characteristic curves discharge pump ME-115
p [inch Hg a]
70
20
60
16
50
40
12
60
BluVac VI-55-BV
30
[feet]
30
8
20
40
20
20
4
10
0
33
40
60
80 100
200
300
400
600
900
Inlet pressure p [mbar]
0
0
1
2
3
4
5
6
7
8
9
10
11
Flow rate Q [m /h]
3
Test conditions of the vacuum pump
Test conditions of the discharge pump
The characeteristic curves are applicable for the compression of
20 °C (68 °F) dry air from inlet pressure to atmospheric pressure
(1013 mbar/ 30 inch Hg a).
The tolerance of the suction capacity is - 10%. Ring liquid is water at
15 °C (59 °F).
With different operating conditions performance characteristics
change (e. g. differing gas or operating liquid conditions).
The characeteristic curves are applicable for the delivery of water
of 20 °C (68 °F) temperature.
The tolerance of the total head and capacity is ± 10%.
If the property of the pump medium differs, the characteristic curves
change.
Type code
VI
Example 
-55
-55
-BV
Type (type of the vacuum pump in use)
Size (size of the vacuum pump in use)
T1 Material design
T2 Version
T1: Code material design
T2: Code version
Code number
55
Code number
BV
BV-I
Denomination
BluVac
BluVac-Insert
Pump
Vacuum pump
Discharge pump
Casing cover
1.4308
CrNi-cast steel
EN-GJL-250
Cast iron
Vacuum pump with
frequency converter


Inter casing
1.4301
CrNi-steel
-
Pressure level sensor


CuSn
PP
Operating panel


1.4122
CrMo-steel
1.4122
CrMo-steel
Discharge pump with
frequency converter


Double-mechanical
seal housing


Water level sensor


Separator tank

-
Impeller
Shaft
Double-mechanical
seal housing
Mechanical seal
6
EN-GJL-250
Cast iron
Carbon, Cr-steel, NBR
Carbon, Ceramics, NBR
Subject to technical modifications and error.
11/2013 | 1096.1044
Technical data
520
320
(100)
R6
Ue3 (2 x)
356
B
R6
370
Dimensional drawing
R6
R6
180
310
L
G 1 1/2
UDV
485
210
30
30
70
22
222
225
Ue1
5
UR
Ue2 (2 x)
UDW
295
441
372
UF
Data and dimensions
BluVac
Vacuum pumps
Discharge pump
Dimensions
Connections
Type
Type
Type
B
L
UDV
SAE 1 1/4
Pressure connection vacuum pump
VI-55-55-BV
VI-551
>370
664
UDW
SAE 1 1/4
Pressure connection discharge pump
VI-130-55-BV
VI-1301
400
684
Ue1
G 1/2
Connection for drainage (drainage of separator)
Ue2
G 1/2
Connection for drainage (drainage of vacuum pump)
Ue3
G 1/2
Connection for drainage (drainage of water pump)
UF
G 1/4
Connection for fresh liquid supply of the vacuum pump
UR
0 121 mm
Maintenance opening
1Valve-free
ME-115
version
30,2
69
80
58,7
Technical data for BluLine vacuum units with vacuum pumps or side channel blowers upon request.
1096.1044 | 11/2013
Subject to technical modifications and error.
7
11/2013 – 1096.1044
Speck Pumpen Vakuumtechnik GmbH
Postfach 1453 · 91142 Roth / Germany
Regensburger Ring 6 - 8 · 91154 Roth / Germany
Tel.: +49 (91 71) 809 - 0
Fax: +49 (91 71) 809 - 10
[email protected]
www.speck.de