Puyan Custom Rotary Vane Vacuum System - Shipyard Case
In large-scale industrial scenarios such as shipbuilding and heavy equipment assembly, the stability and reliability of vacuum systems directly impact production yield and efficiency. Recently, Shanghai Puyan Mechanical Equipment Co., Ltd. (hereinafter referred to as "Puyan Machinery") successfully delivered a customized rotary vane vacuum system to a major shipbuilding factory in Dalian, effectively solving the customer's problems of insufficient vacuum sources and operational fluctuations.
Project Background: Stringent Vacuum Requirements in Shipbuilding
Shipbuilding factories involve multiple processes such as hull welding, composite material forming, pre-painting treatment, vacuum lifting, and air tightness testing, requiring a vacuum source with "large flow, high vacuum, and continuous operation". Additionally, the operating environment often includes complex factors like dust, high temperatures, and vibrations, making standard single-stage vacuum pumps difficult to perform reliably over the long term.
The Dalian customer had previously experienced issues such as rapid pumping speed decline, frequent maintenance, and insufficient buffer capacity, leading to intermittent production line stoppages. Therefore, the customer explicitly requested a rotary vane vacuum system that not only provides continuous suction capacity but also has adequate buffering and intelligent control functions.
Puyan Solution: PV100 Rotary Vane Vacuum Pump + 1m³ Horizontal Buffer Tank
After on-site investigation, Puyan Machinery's technical team customized the following configuration for the shipbuilding factory:
- Core Vacuum Source: Puyan Rotary Vane Vacuum Pump PV100
The PV100 is a mature model from Puyan Machinery, featuring high-precision vane structure and forced oil lubrication. It achieves an ultimate vacuum below 0.5 mbar and a pumping speed of 100 m³/h (expandable in parallel as needed). The pump offers low noise, low vibration, and moisture resistance, making it especially suitable for long-term continuous operation in shipbuilding factories. - Buffer and Separation System: 1m³ Horizontal Buffer Tank
The 1-cubic-meter horizontal buffer tank effectively smooths vacuum fluctuations and captures any fine dust or liquid impurities that may enter from the pipeline inlet, protecting the vacuum pump for long-term stable operation. The tank is designed in accordance with pressure vessel standards and comes standard with a drain valve and vacuum gauge port. - Control System: Optional PLC automatic start/stop and remote monitoring, which automatically adjust the system's operating status based on air demand, further saving energy.
The complete system adopts a skid-mounted structure, prefabricated at the factory and ready for use by connecting pipelines on site, greatly reducing on-site installation and commissioning time.
Project Results: Improved Stability and Maintainability
After the rotary vane vacuum system was put into operation, the vacuum supply in the shipbuilding factory significantly improved:
- Stable vacuum level: During 8 consecutive hours of welding and suction operations, the system's vacuum level remained within ±3% of the set value, with no pressure drop.
- Reduced energy consumption and noise: Compared with the customer's old equipment, system noise decreased by approximately 15 dB, and overall power consumption dropped by about 12%.
- Extended maintenance intervals: The horizontal buffer tank effectively intercepted residual materials in the pipeline, extending the oil change interval of the PV100 vacuum pump from once a month to once per quarter, greatly reducing downtime for maintenance.
The customer's site manager commented: "Puyan's rotary vane vacuum system not only solved the 'vacuum shortage' on our production line, but also is easy to operate and has a low failure rate, truly providing solid support for production continuity."
Why Choose Puyan Machinery's Rotary Vane Vacuum System?
Puyan Machinery focuses on vacuum pumps and customized vacuum systems, with core advantages including on-demand customization (non-standard design based on air volume, vacuum level, media, control requirements, etc.), own-brand quality, and fast response (providing solutions within 24 hours). Besides shipbuilding, this rotary vane vacuum system is also widely applicable to lithium battery vacuum drying, food and pharmaceutical packaging, electronic component pickup, rubber vulcanization degassing, printing and paper conveying industries. If your factory is facing problems such as insufficient vacuum, system instability, or the need for energy-saving upgrades, please contact Puyan Machinery for a customized solution.