2014.05.08 GNJBQ Agitator Manual
Short Description
Agitator Manual Waste Management...
Description
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User Manual GNJBQ Mud Agitator
Hebei GN Solids Control Co.,Ltd
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Hebei GN Solids Control Co., Ltd (FORMERLY KNOWN AS TANGSHAN GUANNENG MACHINERY EQUIPMENT CO., LTD). (Brand Name: GN Solids Control)Is a China API & ISO Certified manufacturer specializing in complete line equipment & shaker screens for:
OIL&GAS Drilling----Solids Control Equipment
HDD&CBM Drilling----Mud Recycling
Oilfield&Industrial--Drilling Waste Management
System
GN Solids Control is one of the most famous International Brand for Mud Solids Control & Drilling Waste Management.
GN is the First API certified solids control equipment manufacturer in China.
GN Facilities total area is over 70,000 ㎡ which is close to Beijing.
GN Products have been exported to 60 countries and regions.
GN Owns a specialized facility for making shaker screens in Asian largest wire mesh center city.
GN
Up to March,2013, GN· is the only China based API Certified manufacturer who provide
Owns 10 patents for the design of Solids Control Equipment.
Vertical Cutting Dryer for drilling waste management.
Complete Line Equipments
GN System: Design & manufacture complete line equipment for a total mud system which ensures better integration of system and competitive price.
GN Solids Control Equipments: Shale Shaker, Mud Cleaner ,Desander ,Desilter, Centrifuge, Agitator, Mixing Hoppers, Flare Igniter, Various Tanks, Pumps, Degassers etc.
GN Drilling Waste Management: Vertical Cutting Dryer,HI-G Dryer Shaker, Decanter Centrifuge,Screw Pumps etc
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GN Main Spare Parts: Shaker Screens, Hydrocyclone Cones, Rig Mat
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Read Before Use
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CONTENTS Complete Line Equipments................................................................................................................ 2 Section 1-Overview ................................................................................................................................... 6 1.1 Operation Instructions .................................................................................................................. 6 1.2 Application ................................................................................................................................... 7 1.3 Features ........................................................................................................................................ 8 1.4 Main parameters of agitator ......................................................................................................... 8 1.5 Usage of mud agitator .................................................................................................................. 8 Section 2- Structure And Operation Principle ........................................................................................... 9 2.1 Drive Motor ............................................................................................................................... 11 2.2 Gear Drive.................................................................................................................................. 11 2.3 Impeller ...................................................................................................................................... 11 2.4 Main parts list for different agitator models .............................................................................. 12 Section 3- Model selection and Installation ............................................................................................. 14 3.1 Model selection .......................................................................................................................... 14 3.2 Operation Attentions .................................................................................................................. 14 3.3 Installation ................................................................................................................................. 15 3.4 Gearbox lubricant level .............................................................................................................. 19 3.5 Electrical connections ................................................................................................................ 20 3.6 Storage & handling .................................................................................................................... 21 Section 4- Machine start up & shutdown ................................................................................................. 22 4.1 Initial startup .............................................................................................................................. 22 4.2 Normal startup and operation..................................................................................................... 22 4.3 Normal shutdown procedure ...................................................................................................... 23 4.4 Emergency shutdown ................................................................................................................. 23 Section 5- Maintenance............................................................................................................................ 24 5.1 Routine maintenance .................................................................................................................. 24 5.2 Gearbox lubrication ................................................................................................................... 24 Section 6- Troubleshooting & Solution ................................................................................................... 26 Section 7- Terms of warranty .................................................................................................................. 28 Section 8- Installation and maintenance log ............................................................................................ 30
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Section 1-Overview This manual provides installation, operation, and maintenance instructions for GN mud agitators. The manual is divided into several parts to assist the user inreadily accessing the information. Personnel responsible for transporting, installing, commissioning, operating, or performing maintenance on this equipment are required to read and understand the instructions provided in this manual. One copy of this manual should be available and accessible at the equipment location. For machine safety and performance, no additions and/or changes may be made to the equipment without the explicit written permission of GN Solids Control. Genuine GN repair/replacement parts are required。
Fig. 1:
GN agitator
1.1 Operation Instructions All persons responsible for operation and maintenance of this equipment must read and
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understand all safety information in this manual prior to operating and/or maintaining the equipment. The safety warnings listed below are included in applicable procedures throughout this manual. a. Read operation manual before operating b. Confirm the oil level in the oil window middle position before starting up. c. To ensure proper balance and orientation when unit is raised and prevent damage to components, attach lifting sling only between motor and gear drive. Do not attempt Lifting by attachment to eyebolt on motor or any other Location. d. Lift specified lifting points to move devices! Ensure that equipment installation fastening, reliable; Fasten all assembly bolt group once a month. Replace lubricates in the gear box every 1000 hours, Brand of lubricating grease: Mobil:150#.; replace grease in the motor every 2500 hours, Brand of lubricating grease: Mobil:EP2. e. Clarify the correct direction of agitator before usage. f. To avoid serious personal injury of un-expected motor startup, be sure equipment is locked out, tagged out, and de-energized prior to install / or maintenance and/or adjustments. DO NOT operate the equipment if defective or faulty mechanical or electrical components are detected.
1.2 Application GN JBQ series mud agitator is one of the important equipment for mud system. It is mainly used for agitating drilling fluids, avoid particle in fluids deposit to tank bottom. GN does not authorize any other use of this equipment, intended usage of the equipment includes compliance with the operating, maintenance, and safety instructions provided in this manual。
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1.3 Features GN JBQ series mud agitator has below features: a. Utilize worm gear reducer. Compact design, perfect joggle and reliable operation. b. Worm gear reducer combined with explosion-proof motor, which enable stable performance in wild severe environment. c. Input shaft of explosion-proof motor are connected to gearbox with elastic coupling directly, rather than belt-drive. It enables stable speed of impeller. d. The mud agitators are high-efficiency mud-mixing units offered in a wide array of custom sizes, and configurations to accommodate virtually any mud tank. It is to avoid over-load of current during start up motor. e. Horizontal type of motor. It is convenient for installation, adjustment or replacement.
1.4 Main parameters of agitator Motor power Model
（kw）
Impeller speed（rpm）
Impeller dia.
Impeller
Weight Ration
Ex Marks
（mm）
Qty
(kg)
GNJBQ030A
3
650
1
100
GNJBQ055A
6.5
850
1
250
950
1
356
800
2
GNJBQ075A 7.5 GNJBQ075A-D
378 EXdllBt4/
60/72 GNJBQ110A
1050 11
1
（50Hz/
GNJBQ110A-D
850
IECEX/
2
60Hz） GNJBQ150A
479 25:1
494 A-TEX
1100
1
684
960
2
702
15 GNJBQ150A-D GNJBQ185A-D
18.5
1050
2
750
GNJBQ220A-D
22
1100
2
780
1.5 Usage of mud agitator It is high-efficiency mud-mixing units offered in a wide array of custom sizes and configurations to accommodate virtually any mud tank. The horizontal drive is designed
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for installations having limited space above the mud tank. The mud agitator stirs mud slurry to maintain suspension of solids. The agitator is mounted on top of the mud tank and has one or two impeller(s) immersed in the mud slurry. The impeller shaft is coupled to an electric drive motor with coupling. iT is available in several horsepower ratings from 7.5hp to 20hp (5.5kw ~ 15kw). Normally, below 11kw agitator, single impeller usually be matched. Above 11kw, double impeller better. Details design should be based on the user’s request and jobsite condition. The impeller is fixed to the shaft with bolts to avoid rotating or sway (connection with key groove optional). Its vertical location on the shaft is determined as a height from the tank bottom corresponding to the impeller diameter times 0.75. For example, a 20” impeller should be mounted 15” above the bottom. GN recommends straight impeller blades for tanks under 5’ deep and canted blades for deeper tanks. If dual impellers are desired, straight blades are mounted on the bottom and the canted blade impeller is installed at a point about two-thirds above the tank bottom. The keyed motor and driven impeller shafts are rigidly connected by a multi-piece coupling, which uses tapered locking bushings to secure the shafts together. Shaft lengths are customized to suit customer specifications. For shafts longer than 8’, a stabilizer is mounted on the tank bottom to support the lower end of the shaft.
Section 2- Structure And Operation Principle GN mud agitator is made of explosion-proof motor, worm gear reducer. impeller,
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mounting plate, elastic coupling, and rigid coupling. Explosion-proof motor and worm gear reducer installed on mounting plate. Elastic coupling connect explosion-proof motor input shaft and gearbox input shaft. Impeller shaft and gearbox output shaft are connected by rigid coupling. Although the arrangement mud agitator components is identical across the various sizes and configurations, the drive motor, impeller, shaft length and diameter, gear drive, and motor orientation vary between models. Figure 2 shows the typical components of a mud agitator. The configuration for the same power rating is identical, except for the type of ear drive. The unit is shipped unassembled and requires assembly by a trained, qualified technician.
Fig. 2: Main components of GN mud agitator S/C 7 6
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Part No. M20X80botls assembly Motor & worm gear component
Description reducer
Qty 4 1
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5 4
M14X140 Impeller installation bolt Stabilizer
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Impeller
2 1
M14X70 Shaft installation bolt Agitator shaft
2 1 Single Layers
or
double
1-2 6 1
2.1 Drive Motor The mud agitator is operated by a 3-phase induction motor. Drive motors range from 7.5 to 20 horsepower with customized hz and voltage; the power requirements are specified on the customer order. Electric power, switching, and safety devices are provided by the customer. GN can offer starter for agitator as request. All components come from Siemens of Schneider.
2.2 Gear Drive Rotation of the drive motor is transferred to the impeller shaft through the directly coupled gear drive. The drive is a reduction gearbox and is factory assembled to the drive motor. The drive is sized to apply the maximum torque required to produce the design impeller rotation speed of 60 rpm under 50hz, and 72 rpm under 60hz.
2.3 Impeller Impellers are available in diameters ranging from 650mm to 1100mm to meet the needs of various size mud tanks. The impeller diameter is generally determined by the size of the tank. Larger or deeper tanks employ dual impeller units having a secondary impeller mounted closer to the mud surface. The impeller is mounted on the shaft using a tapered locking bushing. A bolt / key inserted in the impeller shaft locks the impeller to the shaft and prevents rotation. Canted impeller blades are desirable near the bottom of tanks more than 1500mm (5’) deep or where other forces of flow factor may be absent in the tank.
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Fig.3: Canted Impeller
2.4 Main parts list for different agitator models S/C
Model
GNJBQ03 0A
1
GNJBQ05 5A
2
GNJBQ07 5A
3
GNJBQ07 5A-D
4
GNJBQ11 0A
5
GNJBQ11 0A-D
6
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Main parts
Part No.
Specs
Qty
Motor & Gearbox Assembly
GNJBQ030-01
Subassembly
1
Shaft
GNJBQ055-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNHJYL65-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ055-01
Subassembly
1
Shaft
GNJBQ055-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNHJYL85-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ075-01
Subassembly
1
Shaft
GNJBQ055-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNZZYL95-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ075-01
Subassembly
1
Shaft
GNJBQ075D-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNZZYL80-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ110-01
Subassembly
1
Shaft
GNJBQ055-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNHJYL105-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ110-01
Subassembly
1
Shaft
GNJBQ075D-02
Welding Assembly
1
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GNJBQ15 0A
7
GNJBQ15 0A-D
8
GNJBQ18 5A-D
9
GNJBQ22 0A-D
10
Interchang eable parts
11
13
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNZZYL85-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ150-01
Subassembly
1
Shaft
GNJBQ150-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNHJYL110-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ150-01
Subassembly
1
Shaft
GNJBQ150D-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNZZYL95-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ185-01
Subassembly
1
Shaft
GNJBQ150D-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNHJYL105-00
ZG35#
1
Motor & Gearbox Assembly
GNJBQ185-01
Subassembly
1
Shaft
GNJBQ150D-02
Welding Assembly
1
Stablilizer
GNJBQ055-03
SUS316
1
Impeller
GNHJYL110-00
ZG35#
1
Shaft linking bolts
GB/T 5783 M14×70
SUS316
6
Impeller fasten bolts
GB/T 41 M14
SUS316
2
Impeller fasten spring washer
GB/T 93 14
SUS316
8
Impeller fasten bolts
GB/T 5783 M14×140
SUS316
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Section 3- Model selection and Installation Before installation / disassembly, read and understand all safety information presented in this manual and associated documents. Review the equipment handling procedures in the manual. Pay particular attention to information concerning “lift points” and the use of spreader bars before lifting or moving the equipment. Failure to observe proper equipment handling procedures may result in serious personal injury and/or damage to the equipment.
3.1 Model selection For proper mixing and suspension of solids, the mud agitator must be properly sized and installed. To properly size a mud agitator, proceed as follows: 1). Select desired style – horizontal type 2). Determine available electric power - 440V/460V/380, 60HZ , 380V/400V/415V, 50HZ or customized. 3). Select horsepower and impeller(s) as determined by the following factors: a. Tank design - round or square b. Tank dimensions c. Maximum mud weight d. Desired turnover ratio (TOR) After gathering the required information, the agitator can be properly sized to meet the horsepower demand and correct agitation for the application. To ensure accurate sizing, GN recommends clients to communicate with GN people to make sure size and model.
3.2 Operation Attentions Following are operational recommendations for mud agitators: 1. Maintain uniform tank dimensions, i.e. equal width-to-length ratio or as close as possible to equal.
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2. Avoid TOR values greater than 85 seconds, as this may jeopardize solids suspension. 3. Avoid TOR values less than 40 seconds, as this may result in formation of a vortex and increase air entrapment.
3.3 Installation Following are the sequential steps of the mud agitator installation procedure. The sequence presented is a guideline and may vary depending on the user’s facilities, previous experience with this equipment, and optional equipment. 1. Read and understand all safety information & handling procedures in this manual, and identify the mud agitator components. 2. Locate and weld mounting plate and stabilizer (if required) to tank structure. 3. Place shaft in tank, and assemble impeller(s), tapered bushings, and male coupling on shaft. 4. Install female coupling on gearbox shaft. 5. Install motor and gearbox assembly, and attach shaft coupling to gearbox coupling. 6. Connect electric power supply to drive motor.
Leveling To prevent undue premature wear on the gearbox or coupling and ensure long-term reliability and efficiency of the mud agitator, the impeller shaft should rotate in a true vertical orientation, with concentricity
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